Flexo industry tests print on PCR substrates

A two-day flexographic printing symposium hosted by Follmann at its Technology and Knowledge Center in Minden, Germany, has demonstrated high-quality print results on transparent PCR-based PE film with more than 90 percent post-consumer recycled content, suggesting that demanding consumer packaging graphics on high-recycled content substrates may be more achievable than the industry has previously assumed.

The Next Generation Sustainable Flexo Symposium, held in May 2026 with live CI flexo production demonstrations at Allstein in Herford, brought together technology partners including Esko, Asahi Kasei Photoproducts, tesa, Petroplast, Polifilm, Parmarco, OCS Optical Control Systems and Follmann.

The demonstrations covered reverse and surface printing on transparent OPP films, MDO-PE and PCR-based PE materials and paper-based packaging substrates, integrating water-wash plate technology, water-based flexographic inks, precision anilox technology and automated plate-to-press processes.

PCR flexible packaging with high recycled content has traditionally been limited to simple applications such as courier envelopes and transport packaging, where visible haze and material inconsistencies constrained print quality. The symposium findings indicate that advances in plate technology, screening, press stability and workflow optimization across the full flexographic supply chain are beginning to change that picture.

The results are particularly relevant ahead of PPWR mandates expected to require a minimum of 30 percent recycled content in packaging from 2030, with targets rising thereafter. A key takeaway from the event was that progress depends on collaboration across the entire flexographic ecosystem rather than any single technology.