Paxxus invests in Bobst Master M6

US-based Paxxus has installed its second Bobst Master M6 in-line flexo press at its Irish facility in County Cork, to enhance and streamline its production of healthcare packaging significantly. The first one, a 7-color model, was installed in 2023, and a 4-color model was installed in 2024. Paxxus has positioned itself for both maximum flexibility and long-term operational resilience.
 
Paxxus is among the leading global suppliers of engineered flexible materials and packaging for the worldwide healthcare market, recognized for its expertise in high-barrier films, foils, composites and peelable materials. Paxxus supports the entire healthcare industry, serving pharmaceutical, medical device, diagnostic and related sectors.
 
Before investing in the Bobst presses, Paxxus Ireland was running two aging flexo machines dating back to 1997 and 2004, respectively. 'We got everything we could out of them,' said Ciaran Foley, managing director at Paxxus Ireland. 'But we knew we needed to step up. We weren’t just replacing physical machines; we were upgrading the entire way we work.'
 
The decision to go with Bobst came after an extensive evaluation. The business sought flexo machines that could deliver premium print quality, fast changeovers, and reliable diagnostics, all of which are critical factors for their low-volume, quick-turnaround, precision-focused healthcare packaging work.
  
Bobst's engineering pedigree and sensor-rich design made a compelling case. 'You need machines that just do what they say on the tin,' shared Foley. 'The remote diagnostic capabilities, simplicity of access, and flexibility for add-ons like die-cut lidding and embossing - all that tipped the scale.'
 
A particularly important factor was the ability to change over quickly, in tandem with high running speed. As Foley explained, 'With lower-volume, quick-changeover tasks, we don’t want a machine sitting idling for 10-15 minutes on setup before production even begins. That can be the difference between a profit and a loss on some jobs.
 
'With the Bobst Master M6, we’re more productive. Our previous flexo machines typically ran at speeds of between 50 and 90 metres per minute. With our new M6 machines, run speed is typically 80 to 140 meters per minute.'
 
Paxxus customized its 7-color Master M6 with modules for 2-sided printing, pyramid embossing and die-cutting, enabling a wider product offering for blister lids and calendar packs. The 4-color M6, installed later, further enhanced the company’s capabilities in high-volume, lower-colour healthcare SKUs.
 
A key advantage for Paxxus was the machine's connectivity. The company praised how Bobst technicians could fine-tune its work.
 
Foley estimated the company is now running jobs 35–40 percent faster, with changeovers significantly quicker compared to previous technology. Beyond speed, the shift has improved ergonomics for operators.
 
'With our old presses, changing out heavy rollers was strenuous for our operators. They were heavy and not particularly easy to handle. The new Bobst setup is not only lighter but designed for better accessibility,' Foley explained. 'That’s critical in today’s market where skilled labour is hard to find and keep.'
 
In addition to seamlessly integrating into the company’s cleanroom operations, Bobst's machines have also proven compatible with Paxxus' dual curing system requirements (LED and conventional UV), producing highly durable prints across aluminum, polyester, and Tyvek substrates, which are essential for blister lids and other healthcare packaging applications.
 
Both Bobst Master M6 presses can run a wide range of materials, from 12-micron polyester to complex laminates and even 360-micron PET.
 
The decision to standardize on Bobst brings efficiency through shared tooling and operator training, while future-proofing the plant for evolving customer needs.
 
With Bobst, Paxxus found not just a technology vendor, but a long-term technical partner. 'It’s not about promises on paper,' concluded Foley. 'We saw the M6 in action. It looked the part, performed the part, and Bobst backed it with the right support. That made our decision easy.'