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Pipi Print and Packaging Ltd

Pipi Print and Packaging Ltd enhances capabilities with Fujifilm Jet Press 720S Investment

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Pipi Print and Packaging, based in Leicestershire, UK, is proud to announce the successful installation of its first digital press, the Fujifilm Jet Press 720S. This investment, initiated in March and fully operational since July, highlights the company’s commitment to innovation and sustainability in the packaging sector.

Pipi Print and Packaging is a family-owned business established in 1982, beginning as a small commercial print operation run from a terraced house. Over the years, it has grown into a major provider of printed cartons and labels, now operating from a 42,000-square-foot manufacturing plant. Serving a wide range of industries, including cosmetics, healthcare, decorative, and pharmaceuticals, Pipi Print and Packaging is renowned for its high quality, bespoke packaging solutions.

Hitesh Parmar, Sales Director, at Pipi Print and Packaging, comments: “The decision to invest in the Fujifilm Jet Press 720S was driven by the need to improve production speed, reduce waste, and maintain superior colour consistency. As our first investment in a digital press, the Jet Press 720S has revolutionised our operation. This efficiency, along with the excellent colour consistency and reduced waste, is a significant advancement for our company.

“This new capability has allowed us to enhance our service offerings, particularly by enabling lower minimum order quantities (MOQs), making us an ideal partner for start-up brands. The investment aligns with our commitment to sustainability, as the Jet Press 720S significantly reduces paper waste and eliminates the need for extensive make-ready sheets.” He added.

Raj Parmar, Managing Director, at Pipi Print and Packaging, comments: “This is a groundbreaking investment for us which has quickly revolutionised our work flow. The turnaround times from artwork approval have proven to be phenomenal. We look forward to building a long term partnership with Fujifilm.”

Martin Fairweather, National Digital Business Development Manager, Fujifilm UK said, “We are delighted that Pipi Print and Packaging has chosen the Jet Press 720S to enhance their digital printing capabilities. It’s been a pleasure to work with such a forward-thinking company that values both quality and sustainability. We are confident that this press will help them achieve their operational goals and open up new opportunities in the packaging market.”

Pipi Print and Packaging will be showcasing their latest investment and discussing its benefits at London Packaging Week. Visitors are encouraged to stop by their stand F14 to learn more about how they can benefit from Pipi Print and Packaging’s service offering with the Fujifilm Jet Press 720S

‘Zero to Landfill’ certification for ink site

Fujifilm’s Broadstairs ink manufacturing site receives Valpak ‘Zero to Landfill’ certification

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Fujifilm’s ink manufacturing site, based in Broadstairs, UK, has received ‘Zero to Landfill’ certification from Valpak, a leading provider of environmental compliance and recycling solutions.

The award-winning factory* manufactures high performance inks for a range of markets, including Uvijet wide format UV inkjet inks, and Sericol screen inks. The company has steadily implemented new systems, technologies and processes at the site to monitor and measure its progress, as it takes steps to further reduce its environmental impact.

The Valpak certification is a significant milestone that confirms the site is sending zero packaging, production or hazardous waste to landfill. It also highlights the company’s commitment to continuously improving its waste management through reducing, recycling and reusing resources.

The certification process involved a comprehensive audit, carried out by Valpak, of Fujifilm’s waste management practices on site, including its waste and recycling initiatives.

During the audit, Fujifilm demonstrated how it is measuring and monitoring a wide range of key performance indicators, including:
• Waste in each department is properly and responsibly disposed of in the correct bins
• Hazardous waste containers are sealed, once full, and removed by the onsite waste management team
• Balers are used for plastic polythene and cardboard
• The canteen has separate bins for metal cans, coffee cups, food and general waste
• Food waste is composted
• There are mixed recycling bins in place across the site
• Importantly, Fujifilm records its waste data via an online system to measure and improve its practices.

In addition, Paul Dannahy, Goods Team Leader at the site in Broadstairs, played a key role in identifying waste processing companies which allowed Fujifilm to move waste from incineration to recycling centres, and in other areas, generate value from the waste. (For example, pallets were broken down into pellets for fuel. The pellets were then sent away from the site, sold and reused in other applications).

Fujifilm proved (from 1 April, 2023 to 31 March, 2024) that in addition to sending zero waste to landfill, it achieved a recycling rate of 53.64%. In addition to increasing the amount of waste being recycled, Fujifilm also reduced the overall waste being produced.

 

Paul Dannahy, Goods Team Leader comments: “We are honoured to receive ‘Zero to Landfill’ certification from Valpak. It’s a testament to our team’s dedication to reducing our environmental impact and promoting a circular economy.”

Craig Milsted, Sustainability Advisor at Fujifilm Speciality Ink Systems, Broadstairs, adds: “Looking forward, we are confident that we can continue to make iterative improvements all over the site, across all areas of energy, waste and water reductions, to maintain our position as an award-winning, world-class and sustainable factory.”

 

Bronwynn Harris, Waste & Resource Traceability Consultant at Valpak, adds: “We are delighted to certify Fujifilm’s Broadstairs site with ‘Zero to Landfill’ status. The company’s commitment to sustainability and the team’s proactive approach to waste management serve as an exemplary model for other companies to follow. The achievement highlights the significant impact that dedicated waste management practices can have on our planet.”

* Winner of ‘Best Factory’ award in 2013, 2015, 2016 and 2017

Acuity Prime Hybrid

Een echte hybride oplossing

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De snel veranderende markt voor signs & displays heeft behoefte aan flexibele oplossingen die de vraag kunnen bijbenen. Hoewel er nog steeds verbeteringen in snelheid en kwaliteit worden behaald, zijn die van steeds minder betekenis. Op het gebied van prijs-kwaliteitverhouding en veelzijdigheid liggen de mogelijkheden voor echte differentiatie.

Als gevolg van de Covid-pandemie ontstond een deel van deze verschuiving naar steeds grotere veelzijdigheid. Gespecialiseerde printserviceproviders werden gedwongen zich aan te passen en te investeren in nieuwe soorten technologie om nieuwe markten te bedienen met een diverser scala aan toepassingen.

Een van de reacties van de markt op deze verschuiving is een aanzienlijke toename van de belangstelling voor hybride printers en de duidelijke voordelen die ze bieden qua flexibiliteit en veelzijdigheid. Toen Fujifilm in 2021 zijn Acuity-assortiment grootformaatprinters van de grond af opnieuw ontwierp, was dat voor een deel om beter te kunnen inspelen op dit soort marktverschuivingen. De Acuity Ultra Hybrid LED en Acuity Prime Hybrid zijn het eerste bewijs dat deze strategie werkt zoals gepland.

De echte hybride printer opent een scala aan mogelijkheden voor drukkerijen die op zoek zijn naar groeimogelijkheden. Zo'n printer kan meer en sneller produceren.

 

fujifilm wide format printer

Een echt hybride platform

Wat bedoelen we met ‘echt hybride’? Wat is er nu eigenlijk ‘echt hybride’ aan deze printer? Los van het voor de hand liggende antwoord: kunnen printen op een breed scala aan zowel stijve als flexibele substraten. Misschien kunnen we die vraag beantwoorden door eerst te behandelen wat het platform niet is. Het is geen flatbedprinter met rotatiemogelijkheid, en het is ook geen rol-to-rol pers met een flatbedoptie. Voor dat soort machines bestaat een markt, maar eigenlijk alleen in omgevingen waar die aanvullende functionaliteit slecht af en toe nodig is. In de huidige printmarkt – waar het van het grootste belang is om een zo breed mogelijk scala aan werk te kunnen inpassen – zijn deze halfbakken oplossingen vaak niet meer toereikend.

Met een echte hybride krijgt u uitzonderlijke prestaties, of u nu op harde media of op rolmedia afdrukt, omdat de machine ontworpen is met beide in gedachten, in plaats van dat een van de twee gewoon een extra toevoeging is. En als de bouwkwaliteit van de machine goed genoeg is, dan blijven die uitzonderlijke prestaties consistent, zelfs bij zeer lange opdrachten, of het nu gaat om rol-naar-rol of harde media, wat de ultieme flexibiliteit biedt.

De echte hybride printer opent een scala aan mogelijkheden voor drukkerijen die op zoek zijn naar groeimogelijkheden. Zo'n printer kan meer en sneller produceren.

Ontwerp en bouw

Fujifilms Acuity-lijn combineert een bekroond Brits ontwerp met Japanse kwaliteitszorg en nauwgezette productieprocessen. De uitzonderlijke ontwerp- en bouwkwaliteiten zijn waarneembaar in alle aspecten van de prestaties van de machine. Maar de Acuity Prime Hybrid blinkt toch vooral uit in zijn mediaverwerkingsvermogen, wat de printer een treffend voorbeeld maakt van een ‘echte hybride printer’. Dankzij de industriële bouwkwaliteit van de Acuity Prime Hybrid kan de printer rollen tot 100 kg verwerken, veel zwaarder dan een gemodificeerde flatbedprinter aankan. En dat is niet het enige. De Printer monitort de productie ook uitzonderlijk goed, wat betekent dat de machine lange opdrachten kan printen met minimale tussenkomst van de operator.

Inkten van wereldklasse

Als het gaat om inkt en droging heeft de Acuity Prime Hybrid nog een voordeel ten opzichte van veel zijn concurrenten. Fujifilms eigen UV- en energiezuinige LED UV-inkten maken de Acuity Prime Hybrid niet alleen sneller dan veel van zijn concurrenten, maar ook geschikt voor het printen op een veel breder scala aan substraten. Dit komt omdat droging met lage energie gelijkstaat aan weinig warmte, wat betekent dat gevoelige media veel gemakkelijker en bij hogere snelheden kunnen worden bedrukt. Dat is onmogelijk bij systemen die een heter droogproces vereisen, bijvoorbeeld latexinkt. Minder warmte betekent natuurlijk ook minder energieverbruik, wat weer zorgt voor minder energiekosten. Zo zijn er zowel milieuvoordelen als potentiële kostenbesparingen, zonder dat dit de productie negatief beïnvloedt.

Belangrijk is dat de uv-inkjetinkten van Fujifilm ook Greenguard Gold-gecertificeerd zijn, wat ze geschikt maakt voor een reeks interieurtoepassingen waaronder wandbekledingen.

Werkelijke veelzijdigheid

De Acuity Prime Hybrid onderscheidt zich ook door zijn printbreedte van 2,05 m, veel meer dan de standaard 1,6 m van de meeste alternatieven. Deze extra capaciteit maakt de machine niet duurder, waardoor het een praktische keuze is voor bedrijven die nieuwe markten willen verkennen. De grotere printbreedte van de machine biedt de mogelijkheid om rollen van verschillende formaten efficiënt te printen, evenals de mogelijkheid om meerdere platen naast elkaar te laten lopen – terwijl de noodzaak voor bijsnijden of formaat wijzigen afneemt, wat zowel tijd als middelen bespaart. Deze veelzijdigheid opent deuren naar een groot aantal toepassingen, van winkelsigns tot buitendisplays.

In een tijd waarin aanpassingsvermogen van vitaal belang is, biedt de Acuity Prime Hybrid de ideale oplossing voor drukkerijen om concurrerend te blijven en te reageren op de steeds veranderende markt.

Bewezen oplossing

De Acuity Prime Hybrid bewijst nu al zijn waarde in de praktijk.

David Allen, directeur van Allen Signs uit het Verenigd Koninkrijk, was in 2023 de eerste ter wereld die investeerde in deze machine. Hij stelt dat de printer door zijn uitstekende mediaverwerking niet alleen opviel tussen concurrenten, maar ook in staat is om op een kosteneffectieve manier te printen op moeilijke substraten, zoals metaalhoudende materialen.

David Allen: “Omdat we al bekend waren met hybride platforms, bood de Acuity Prime Hybrid een uitgelezen kans om het merk Fujifilm verder te verkennen. De printer stelt ons in staat om onze normale productie uit te voeren met minimaal oponthoud en uitstekende inktprestaties.”

Matt Ryder, printspecialist bij Allen Signs voegt daaraan toe: “We hebben de nieuwe Fujifilm-machine uitgeprobeerd en dat ging direct volgens verwachting. Het ging perfect. Qua materialen zijn we nog geen substraat tegengekomen dat niet geschikt is.”

Allen Signs is de eerste van vele bedrijven in Europa en de rest van de wereld die profiteren van een machine die zowel een echte hybride is als baanbrekend voor printproductie in grootformaat.

Acuity Prime Hybrid

Ontdek de baanbrekende grootformaat hybride printer geschikt voor een groot aantal creatieve toepassingen.

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The Best of Inkjet and Toner

Two digital print technologies. Multiple solutions. One partner.

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In the commercial print market today, analogue printing processes, especially lithographic offset, still rule in terms of the volume and value of materials printed. However, that volume and value are falling as demand rises for personalised materials printed on demand and in smaller but more frequent numbers. These demands can only be met by digital print.

Market researcher Smithers tells us that in 2032 digital print will be worth $230.5 billion, accounting for almost a quarter of the global value of all print and printed packaging. This is a little under 3.0 trillion A4 prints, an increase of 68.6% on the 2022 market. [1] And within that figure for digital printing, inkjet accounted for 61.4% of digital print value with 62.4% of volume in 2022. This will increase to 74.1% of value and 77.5% of volume in 2032.[2]

As the commercial print sector continues to digitise, businesses have a choice when it comes to the best digital print technologies to take them forward. For some, the speed and quality of inkjet will be paramount, while for others, the added flexibility of toner and the ability to print special colours and special effects for creative applications will be of greater utility.

For many, a combination of both technologies will be the answer.

Fujifilm is unique in offering best-in-class solutions and decades of experience in the development of both inkjet and toner technologies, so whichever digital path a company takes, Fujifilm has both the product portfolio and the expertise to support.

Furthermore, Fujifilm’s analogue print heritage means that it understands the process and challenges of introducing digital print technologies into a business in a way that digital-only rivals cannot.

When all these factors are considered, there is no better partner in the market to support with digital transformation.

The Fujifilm inkjet story

The story of Fujifilm and inkjet technology is a story in many parts. There are the printheads; the UV and water-based inkjet inks, and the sophisticated integration and optimisation technologies that tie it all together. Fujifilm inkjet technologies power printing solutions like the Jet Press 750S, which has been setting the standard for quality and reliability in digital print production in the commercial sector for a decade, as well as a range of inkjet production solutions for the sign and display and label and packaging sectors.

Printheads

Fujifilm Dimatix is one of the most recognisable and respected brands in inkjet printhead development. The company began in 1984 as Spectra, Inc., a very early pioneer of industrial inkjet printheads. In 2005 it changed its name to Dimatix before being acquired by Fujifilm the following year. Fujifilm itself is renowned for its history of innovation, particularly the way in which it rapidly diversified when the bottom fell out of the photographic film market in the early 2000s. That drive to innovate has continued apace, and the acquisition of Dimatix was part of Fujifilm’s strategy to build arguably the strongest and most diverse inkjet technology platforms in the industry.

Water-based inkjet inks

Fujifilm is one of the few companies in the world with significant R&D and manufacturing capabilities in both water-based and UV inks for the commercial, wide format and packaging sectors.  Fujifilm’s development of water-based inks for commercial applications in particular began in earnest in 2005 with the acquisition of Avecia’s Inkjet Business. A specialist in the development and manufacture of high performance dyes, pigments and colorants, Avecia (now Fujifilm Imaging Colorants) was founded in 1985 with the launch of the first generation of high purity inkjet colorants, and by 1994 it had built the world’s largest digital aqueous ink manufacturing facility in the USA.

With the 2005 Fujifilm acquisition and the massive investment in R&D that followed, more recent developments have produced a raft of new capabilities, including photo-grade dyes for image permanence of 50+ fifty years, proprietary reactive dispersant technologies, and the development of ultra-high performance aqueous inks for Fujifilm’s flagship B2 inkjet press, the Jet Press 750S.

Fujifilm Imaging Colorants, as a result of this consistent and continuous innovation, is a business that has grown to be the world’s largest manufacturer of aqueous inkjet fluids.

The Fujifilm toner story

It may not be widely known to a European audience, but Fujifilm has a long history of introducing innovative toner-based office copiers, monochrome printers and full colour commercial printing systems, alongside significant document and business service solutions. Historically this technology was developed through its Fuji Xerox subsidiary, now called FUJIFILM Business Innovation Corporation.

Although initially a joint venture with Rank Xerox (later Xerox), the business was consolidated to the Fujifilm Group in 2001 when it acquired 75% of the equity, and became a wholly owned Fujifilm subsidiary in 2019 when it acquired the final 25%.

In the last 60 years since, Fujifilm has developed world-leading expertise in toner-based technologies, which now include the high performance EA-Eco toners and fusing systems, the laser imaging and registration systems, the screening and smoothing algorithms, and the finishing and post-processing systems. Many of these technologies are best-in-class, resulting in industry-leading printer performance.

Fujifilm toner technologies

Just as with its inkjet offering, Fujifilm’s ability to bring award-winning toner press solutions to market stems from its fundamental technology expertise, and its ability to bring them together into leading production solutions.

This new range takes full advantage of Fujifilm’s leading heritage in toner-based print production, along with the company’s deep understanding of both offset and digital print, to create production printers that deliver industry-leading performance. They combine high print speeds, superb finishing flexibility, industry-leading colours and enhancements, and of course superb print quality.

The flagship press in the range is the Revoria Press PC1120, which features an advanced print engine and the choice of 10 colours, including gold, silver, white, pink & clear, easily configurable into six before and after CMYK stations. With industry leading print quality, incredible media & finishing versatility, and the largest colour gamut, this award-winning press has made a huge impact in the short time since its phased European launch, giving designers and brands the freedom to create high value print using special colours over short or medium run lengths. With the silver and gold metallics, and the white and special colours and effects available, designers can meet the demands of luxury brands looking for added value print collateral that can be produced economically in very short runs. In addition, Fujifilm-engineered AI image enhancement means that photographs are auto-enhanced at the printing stage, meaning much less time is required to manually re-touch images.

Bringing it all together

In the modern print marketplace, the only real way to stay competitive is by adding value. Whether that is through creative applications, special effects or simply through ultra-high levels of quality. As consumers reach new levels of digital saturation, print offers more targeted, high-value opportunities.

The focus at Fujifilm is to ensure that we are helping our customers right across the industry take full advantage of those opportunities. Every business has a unique set of challenges and each will have different technology and support requirements to meet and overcome those challenges. That’s why we’ve developed our portfolio to span the entire market, from analogue to digital, from toner to inkjet, so we can partner with print businesses at every stage of their digital print journey – from those yet to make their first digital print investment, to businesses that have already phased out analogue altogether.

Discover the best of inkjet. Discover the best of toner. Discover the difference with Fujifilm.

[1],[2] The Future of Digital Printing to 2032, Smithers Information Ltd, 2022

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The Future of Flexible Packaging is Digital

Introducing the Fujifilm Jet Press FP790

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The future of flexible packaging is digital. The future of flexible packaging is inkjet. The future of flexible packaging is the Fujifilm Jet Press FP790.

While there’s no doubt that in the packaging sector, the adoption of digital print technologies has advanced much more slowly than in other print sectors, the direction of travel is unambiguous. A 2021 Allied Market Research (AMR) report estimated the global digital printed packaging market to be worth $20.6 billion (in 2021) and projected substantial CAGR of 9.1% over ten years, to reach $49.9 billion by 2031.[1]

The report singled out flexible packaging as the segment likely to grow the fastest (from the smallest base) and also indicated that inkjet would grow its share of the digital packaging market overall compared with other digital alternatives, thanks to the levels of quality and productivity that can now be achieved with leading inkjet technologies.

There are a number of trends driving these shifts, and Fujifilm has designed the Jet Press FP790 to address all of them head on. In this article we examine three of the most important of these trends and look at how Fujifilm inkjet technology, and the Jet Press FP790 in particular, is uniquely well suited to address them.

Megatrend One: Sustainability

The challenge of developing more sustainable production practices is being driven by a mix of consumer pressure, government regulation and an increasing sense of environmental responsibility on the part of brands and packaging producers.

Reducing waste and boosting recyclability is an increasing concern for packaging companies and this trend is a major driver behind the adoption of digital technology, as it offers a way to significantly reduce waste and the use of consumables associated with analogue print processes.

Going digital has significant environmental benefits here, as far fewer consumables are used before, during and after the production process compared to traditional flexo production, and there is virtually no waste, resulting in a much smaller ecological footprint.

The consumables required for platemaking and the cleaning of processing equipment, the additional packaging required for those consumables, and the additional energy and water use required for those processes are all eliminated.

Additionally, going digital means shorter runs can be printed economically, so you can print just what you need – leading to much less product waste.

Megatrend Two: Time to market  

Time is money, and modern businesses, and modern consumers, expect instant delivery. New product lines often need to be set up at a moment’s notice and the timescales involved in setting up an analogue production line can sometimes be prohibitive – especially for relatively short run jobs.

This is where digital in the form of inkjet really comes into its own. With no set-up time required, the job gets printed straight away and turnaround times are massively reduced.

Megatrend Three: Rapid rise in SKUs and reduced product lifecycles

The proliferation of SKUs is another factor behind the increasing popularity of inkjet. More unique product lines, combined with shorter product lifecycles, mean that companies frequently end up with excess inventory. This leads to logistics and storage challenges, as well as higher levels of waste and higher costs. Short run production, to print the exact quantity you need and no more, offers a way around this, but it is simply not viable using analogue processes.

Related to this, having the ability to quickly and efficiently produce extremely high quality samples is another benefit of inkjet.

Why the Jet Press FP790?

The trends above are driving the interest in digital production – but not all digital solutions are created equal. There are many solutions out there – but only one is a proven mainstream flexo packaging print alternative.

Built on years of Fujifilm inkjet and packaging sector expertise

It’s in the name. Fujifilm’s Jet Press has been synonymous with inkjet excellence in the commercial print and folding carton packaging sector for more than a decade, and Fujifilm’s expertise in printhead and ink development stretches back much further still.

Fujifilm also has a long history in the flexible packaging industry, developing flexo plates, inks, imprinting bars and LED curing solutions.

In the Jet Press FP790, Fujifilm has brought together that combination of inkjet technology and flexo packaging market knowledge to produce a digital flexible packaging press that is not only setting new standards for quality and productivity – but is also designed to fit seamlessly into a typical flexible packaging  production environment with ease.

High quality Fujifilm water based inkjet ink, with a double white option

Fujifilm is one of the world’s leading ink manufacturers and the water based ink in the Jet Press FP790 draws on that rich heritage. The inks also include a unique double white option in the Jet Press FP790, and this, in particular, sets it apart as a machine suitable for tackling everything from the simplest production that just needs to get done fast, through to jobs that require the very highest standards of quality.

Bewezen oplossing

It may be new to the market, but the Jet Press FP790 has already proven its value and its potential through the endorsement of some of the industry’s most respected software and finishing companies who have signed up as partners. These partners include Henkel and Nordmeccanica for coating and laminating solutions, and HYBRID Software for our XMF Packaging workflow solution which provides automated pre-press functionality to deliver accelerated turnaround times, maximum productivity and reduced operating costs.

These multiple partnerships with respected and experienced industry names are both a vote of confidence in the capabilities of the press, and a means of ensuring that it can fit easily and seamlessly into existing analogue production environments.

But the endorsements don’t stop there. An early UK beta customer had this to say:

“Sustainable packaging design is not just about material choice. It’s about sustainable production and that’s what the Fujifilm Jet Press 790 achieves for us. With high speed and high quality digital printing, the ability to cost-effectively produce short run lengths, and the elimination of plates and make-ready processes, all mean that the Jet Press 790 brings a host of benefits to our business. It enables us to deliver excellence in print performance, eliminate waste and exceed the needs of today’s flexible packaging market with complete flexibility and agility. We are delighted to be the first installation in Europe and we are confident that the press will provide us with significant advantages in what is a highly competitive market.”

No additional investment required

Most digital flexo packaging solutions require a lot more additional investment beyond the press itself. Special substrates that need special adhesives and laminates and considerable downtime for all the associated changeovers. The Jet Press FP790 is designed to fit seamlessly into existing workflows and existing laminating and other finishing systems.

Overall, it’s clear that digital technologies are set to drive the future of flexible packaging. There are several trends causing this shift, and we will see this continue to grow further. Fujifilm is unique in its ability to combine decades of expertise in inkjet and flexible packaging, along with the support and knowledge of its partners, to provide an innovative solution that is truly future-proofing the flexible packaging market, with the Jet Press FP790.

[1] Digital Printing Packaging Market 2031: https://www.alliedmarketresearch.com/digital-printing-packaging-market-A08308

Jet Press FP790

Learn more about our revolutionary digital flexible packaging press.

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World-first: Sustainable cleaning solution

Fujifilm reduces the carbon footprint of its inks with innovative cleaning technology at its Broadstairs ink manufacturing facility

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  • Fujifilm switched to a more environmentally friendly cleaning technology at its Broadstairs ink manufacturing facility.
  • The company partnered with Terrafend, which develops and supplies sustainable cleaning solutions.
  • Fujifilm becomes the first company in the world to install an Ambimization® Proteus machine.
  • Ambimization® technology provides a revolutionary approach to cleaning by combining chemical and mechanical engineering.
  • The water-based cleaning fluids are non-flammable, non-carcinogenic and non-toxic.
  • Since installing the new technology, Fujifilm has significantly reduced its waste, carbon footprint and VOC emissions.

The FUJIFILM Specialty Ink Systems (FSIS) award-winning factory in Broadstairs, UK, manufactures high performance inks for a range of markets, including Uvijet wide format UV inkjet inks, and Sericol screen and flexo inks. The factory has implemented several sustainability initiatives over the last ten years and in the summer of 2022, it became the first ever company to trial the new-to-market Ambimization® fluids and Proteus pot wash machine from Terrafend.

Terrafend’s patented Ambimization® technology combines chemical and mechanical engineering to provide a revolutionary approach to cleaning. Ambimization® water-based fluids are non-flammable, non-carcinogenic and non-toxic. They work at ambient temperatures and can be used repeatedly before reaching end of life, thus reducing workplace risk, energy consumption, and VOCs (Volatile Organic Compounds).

Last year, Fujifilm onboarded Ambimization® technology in its analogue ink department in Broadstairs to clean its UV, water-based and solvent-based ink pots. The use of Ambimization®, in turn enabled Fujifilm to implement the Proteus pot wash machine. These new innovations replaced legacy cleaning equipment that used chemical solvents.

The Proteus machine cleans pots with a water-based Ambimization® fluid in a time-efficient manner, facilitating cost and energy savings, as well as reducing the use of VOCs and creating a safer working environment. It is a sustainable cleaning solution that aligns with Fujifilm’s commitments to promote the use of green technology.

Moving from solvent to water-based cleaning

Fujifilm’s old pot cleaning process involved solvents being sprayed on the walls of the mixing vessels at pressures in excess of 70 bars, thereby removing traces of the ink and decontaminating the surfaces of the pots. This method used around 72,000 litres of chemical-based solvent and generated around 22,000 litres of waste per year.

After the cleaning process, the used solvent, saturated with ink, was pumped into a 24,000 litre storage tank at the Broadstairs site. When full, the tank was drained by a specialist contractor and the solvent waste was removed from the site, via road tanker, to a chemical re-processor. At the re-processor, the waste was separated through distillation, enabling 75% of the solvent to be returned to Fujifilm and used again. A limitation of this method was its inefficiency, with 25% of the material being lost in the recycling process.

In stark contrast, the new Proteus machine and water-based fluids, generate minimal chemical waste and VOCs. With Ambimization®, Fujifilm has managed to reduce solvent waste output at its Broadstairs site. This is not only better for the environment, but safer and more pleasant for the on-site Fujifilm team who handle the ink pots before and after cleaning. Fujifilm has reduced its VOC emissions by 91% since switching to the Proteus and Ambimization® process.

Reduced fire risks & energy consumption

An additional safety benefit of Ambimization® is that it eliminates fire risk – and this is further facilitated by the Proteus machine. With the traditional cleaning method, the solvent formed fine aerosol particles during each cleaning event, because of the high pressure deployed. This created an explosive (ATEX) atmosphere. Although ATEX equipment was installed and steps were taken by staff to reduce this fire risk, the risk still posed a threat.

Moving forward with the more sustainable cleaning solution provided by the Proteus machine, Fujifilm will be able to remove all ATEX rated equipment and save on time that would otherwise have been spent on ATEX health and safety measures within the pot wash area. The Proteus machine is also expected to reduce energy usage by 110,000 kWh per year, making it a hugely worthwhile investment.

Key takeaways

Fujifilm’s ink R&D and manufacturing facility in Broadstairs, Kent, has regularly made the news as a four-time winner of the UK’s Best Process Plant in 2013, 2015, 2016 and 2017, but it is for its sustainability initiatives that it is now rapidly creating waves.

Fujifilm has paved the way for more ink and coating manufacturers to implement Ambimization® by being the first company in the world to pioneer the technology. Since Fujifilm onboarded Ambimization® – and the Proteus pot wash machine – Terrafend has introduced the technology to seven additional international major coating and composite manufacturers.

Switching to Ambimization® has delivered the following objectives:

  1. Provided a green / sustainable pot cleaning process
  2. Reduced VOC emissions at the Broadstairs site
  3. Reduced energy consumption by approximately 110,000 kWh per year during the pot cleaning process
  4. Future-proofed the Broadstairs site’s pot cleaning capability
  5. Eliminated the Broadstairs site’s DSEAR risk

Gary Burgess, Manufacturing and CI Manager at FUJIFILM Speciality Ink Systems, comments: “We’re thrilled to be the first company in the world to have trialled an Ambimization® Proteus machine, installed at our Broadstairs ink manufacturing site. Although the digital ink market continues to grow, screen and flexo inks are still used for a number of printing applications. We’ve taken a step to reduce waste and energy when it comes to cleaning our ink pots. During the process, we’ve also reduced VOC emissions and eliminated the site’s largest risk.”

Emily Cassius, Head of Business Development at Terrafend, adds: “This cleaning technology has huge potential to help leading brands – like Fujifilm – to operate more efficiently while reducing risk, waste and carbon footprints. We are pleased to have helped them boost their sustainability credentials and look forward to a continued partnership.”

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Analogue. Digital. Sustainable.

Fujifilm for packaging: a story in three parts.

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The story of Fujifilm, since its founding in 1930s Japan, has been one of continuous innovation – sometimes incremental, sometimes radical, but always ongoing. Print is one of many sectors that has benefited from that innovation, especially over the past couple of decades as digital technology has made real inroads across the industry. That trend towards digitisation is apparent across the whole print market, but the pace of change differs dramatically from sector to sector.

One sector still in the comparatively early stages of that journey is packaging.

At Fujifilm, we understand how print can add value to packaging and are combining expertise in the very latest digital print technologies with an analogue heritage to create a product portfolio that supports the production of both analogue and digitally printed packaging.

We work with packaging producers whatever the stage of their journey; whether it’s helping them to optimise analogue production lines to maximise efficiency or introduce a digital capability. We don’t do one-size-fits-all – we do the right solution, for the right producer, at the right time. And all our solutions, whether analogue, digital or somewhere in-between, are designed to reduce waste and the use of environmentally harmful chemicals, minimise energy consumption and to be as sustainable as possible.

Analogue

With volumes typically far larger than other print sectors, digital is in its comparative infancy in the world of packaging. This means that not all producers are ready for significant digitisation of their printing operations and almost all that are will go hybrid, retaining significant analogue capability.

But continuing with analogue processes doesn’t mean the technology stands still – far from it. Technology and innovation have a huge role to play in the future of analogue package printing. Fujifilm is a key part of that future, with a constantly evolving analogue product portfolio designed to improve the performance and sustainability of analogue printed packaging.

First, there’s our Flenex FW water-washable flexo plates that eliminate environmentally harmful solvents often used in the plate-making process and are more durable than most alternatives, meaning fewer plate changes and less waste. And the sustainable benefits go hand-in-hand with greater press stability and therefore higher, more consistent quality. Then there’s our range of narrow web inks, which we have been supplying for many years, that have a deserved market reputation for both quality and versatility.

In addition, our retrofittable LuXtreme LED UV curing system, uniquely combining both LED UV curing hardware and a brand new range of LED UV inks, radically reduces energy consumption, eliminates harmful VOCs, requires lower maintenance and produces less waste. This results in lower costs, along with higher, more consistent quality, something that is a welcome bi-product of a lower energy system.

Digital

Fujifilm’s heritage and expertise in digital inkjet technology needs little introduction, but the detail of how this is being applied for packaging applications is less well known. Fujifilm has been a pioneer in inkjet technology since the late 1990s, with multiple solutions for wide format, commercial print and labels and packaging.

The Jet Press 750S High Speed Model has set a new standard for the quality that can be achieved with inkjet technologies. Well-known and highly respected in the commercial print sector, it is also designed to print short-run, folding-carton packaging at exceptionally high levels of quality, with many customers using it exclusively for this purpose.

Fujifilm also offers a wide range of scalable imprinting systems that bring the benefits of digital printing to analogue processes by combining Fujifilm’s proprietary technologies across printheads, ink and transport systems with the company’s in depth integration expertise. Based on Fujifilm’s world-leading Samba piezo-electric printbars, the company’s imprinting solutions allow digital inkjet printing to be integrated directly into existing analogue production lines for a broad range of industrial applications.

The Jet Press FP790 digital flexible packaging press features water-based inkjet technology, making it suitable for food packaging production. Built on decades of Fujifilm inkjet expertise, the Jet Press FP790 is designed to offer a digital alternative to flexo production for mainstream applications and print runs, and meets the strategic needs of businesses faced with the challenge of dealing with a widening variety of products – resulting in a proliferation of SKUs – and shorter delivery times.

Sustainable

As well as looking for a solution that’s the right fit for their business, modern packaging producers and the brands they serve are also looking for a solution that’s right for the planet. That’s why sustainability is one of the threads that links all of our packaging solutions, from analogue to digital and everything in-between.

Our Flenex plates reduce waste and eliminate the use of environmentally harmful solvents altogether, and when combined with our PRC1 filtration unit, water use is also minimised. Our LuXtreme LED UV curing system slashes energy use, and our narrow web Inks are solvent-free and manufactured in the UK at our award-winning Broadstairs factory, where extreme care is taken to ensure all manufacturing and operational processes are as environmentally responsible as possible.

Similarly, our imprinting solutions can breathe new life into an analogue production line, bringing additional functionality without the investment in a new line. Where a new investment is necessary to meet market needs, the Jet Press 750S and Jet Press FP790 digital presses eliminate many of the processes and consumables associated with traditional analogue production. Much has also been written about how the Jet Press 750S can contribute to a more circular economy.

Packaging producers, particularly multi-site global producers, are also looking for lasting partnerships with strong, innovative and highly capable suppliers with ambitions that match their own. Here Fujifilm’s legacy, technology portfolio, size and diversity gives the company a powerful platform to develop leading analogue and digital systems long into the future. With an ambition to support producers with their analogue production today, while leading the transition to digital over the long term, we are excited about our future in packaging and the partnerships we hope to develop.

We’re Fujifilm – we’re analogue, we’re digital and we’re always working to help packaging producers be more sustainable.

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Digital print technology for a circular economy

This white paper has been published by Fujifilm as part of its commitment to deliver technically advanced and sustainable printing solutions for the print industry

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Where does print fit in the circular economy?

From books, newspapers, magazines and brochures to folders, annual reports and packaging, print remains a vital and highly effective branding, marketing and communications tool. But in an age of heightened environmental concern and ‘net zero’ carbon reduction targets, how can print be used in the most efficient and responsible way? In this white paper, we take a look at how the latest digital printing technology is dramatically cutting waste and making recycling much easier.

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Fill out the form to download the full 12 page White Paper

Download the full 12 page White Paper here

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We must do more

As part of the “European Green Deal” project, there is an action plan for the EU to boost the efficient use of resources by moving to a clean, circular economy, restore biodiversity and cut pollution, and be climate neutral by 2050. To achieve this goal, action must be taken at all levels. Switching to renewable energy will, on its own, reduce global greenhouse gas emissions by only 55%. The remaining 45% of emissions come from the way we make and use products, which means working smarter and wasting less.

Fujifilm is committed to fully integrating print into the circular economy. Net zero doesn’t have to mean online only – print will always have a vital role to play, and we’re committed to making sure it can always play that role efficiently, effectively and sustainably.

The way we print is changing

The graphics industry has many analogue techniques which, especially when used for bespoke or short run work, have an enormous impact on the environment.

Now, thanks to the latest developments in digital print technology, there are machines which can print while also:

• Massively reducing raw material use
• Using fewer and more sustainable consumables
• Needing far fewer parts replacing
• Producing less waste
• Consuming less water
• Producing 100% recyclable printed products

This technology is moving print from the linear to the circular economy in which everyone has a role to play in keeping our planet liveable and our prosperity intact.

Revoria PC1120 wins BLI 2022 Pro Award

Triumph for Fujifilm as Revoria Press PC1120 Wins Buyers Lab 2022 Pro Award

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Fujifilm’s new Revoria Press PC1120 recently earned the Keypoint Intelligence ‘Buyers Lab 2022 Pro Award’ in the ‘Outstanding High-Volume CMYK+ Production Device’ category. The Revoria Press PC1120 won the BLI 2022 PRO award for Outstanding High-volume CMYK+ Production Device due to:

  • Six colour stations with before – and after – CMYK capabilities that allow for a wider range of inline creative options than some competitors
  • Outstanding halftone image reproduction with the largest CMYK colour gamut tested to date and a range of speciality colours that help create a broad colour palette
  • Customisable and intuitive print server platform, which enables efficient device/remote management capabilities
  • Outstanding mixed-media workflow performance, with no productivity slowdown, which translates to more work being handled inline in a single job submission

An award-winning set of features

David Sweetnam, Keypoint Intelligence’s Director of EMEA/Asia Research & Lab Services commented: “The extra imaging stations before and after the standard CMYK units, along with the diverse range of toner options, make the device stand out amongst others in this digital arena”. Sweetnam was also impressed with the Revoria Flow PC11 Print Server, describing it as “providing a high level of media management, with seamless integration aided by an excellent user-friendly interface”.

Mark Lawn, Fujifilm Europe’s Head of POD Solutions, comments: “We’re delighted to have received this award, as it represents independent recognition of Fujifilm’s outstanding R&D within this area. Fujifilm has ambitious growth plans and this award fuels our drive to continue to work on our new portfolio of Revoria branded products. We know that many companies in the digital printing industry have relied on Keypoint Intelligence for hands-on testing. Their analyst experience is invaluable and for the Revoria PC1120 to be recognised with such an award marks a major milestone for us, and serves to energise us further in bringing the outstanding technologies in this press to customers to support their growth.”

About Keypoint Intelligence

Keypoint Intelligence is recognised as the industry’s most trusted resource for unbiased information and analysis, and its awards are highly respected due to its impartiality and decades of experience in digital printing.

 

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Download the summary report about why the Revoria PC1120 won the award here..

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Design for Environment

The FUJIFILM Group undertakes environmentally conscious product development based on its design for environment initiative.

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As part of its wider global Sustainable Value Plan 2030 (SVP2030), Fujifilm undertakes environmentally conscious product development based on its design for environment initiative. This considers the entire lifecycle of a product, from procurement, manufacturing, transportation, use to the eventual disposal, to set targets from the perspective of climate change mitigation (reduced power use, etc.). From the design stage, the “Reduce, Reuse & Recycle” principle of resource saving, risk reduction of chemical substances, and biodiversity are all considered as part of the development process.

This approach is applied not only to materials and standalone equipment, but also to software and solutions in a bid to reduce environmental impact in the society as a whole. The Life Cycle Assessment (LCA) is conducted to achieve a quantitative and objective assessment of the environmental impact of a product. The environmental label is also used for active dissemination of information.

“Green Value Products” Certification Program

In an effort to “contribute to resolving environmental issues in society through our products and services,” as set out in the Sustainable Value Plan targeted for FY2030, Fujifilm introduced a “Green Value Products” certification program in FY2018.  This program compliments the company’s existing internal regulations on design for environment, and aims to clarify any product’s environmental values and involves the certification of products exhibiting outstanding environmental credentials.

This certification program sets certain priorities to the certification criteria according to the product category and the use and features of each product through its entire life cycle. Fujifilm then clarifies the environmental value of each product by conducting environmentally conscious design assessments based on such certification criteria at the time of product development. Certain products are then selected for certification based on the total score of each assessment item. These products are reviewed and approved by the Group Certification Council, and finally certified as a Fujifilm “Green Value Product”.

The certification criteria are determined for the entire life cycle of each product with a different weight for each assessment item, by comprehensively assessing the environmental items such as “measures for climate change,” “resource saving and recycling,” “risk minimisation for chemical substances,” and “biodiversity” as well as considering the social requirements for each business/product category.

This certification program is implemented in compliance with the requirements of the international standard “ISO14021 Self-declared Environmental Claims” and obtains the opinions of external experts in order to ensure the objectivity, reliability, and transparency of the program.

Certification ranking and criteria

Fujifilm classifies its products into three certification ranks (diamond, gold, and silver) according to the degree of their contribution to the reduction of environmental impact.

RankCertification criteria
DiamondProducts and services that user their respective industries’ innovative technologies to substantially contribute to reducing environmental impact
GoldProducts and services that reduce environmental impact at their respective industries’ highest level
SilverProducts and services that reduce environmental impact at a higher level than their respective industries’ standard

Product examples

In Fujifilm’s Graphic Arts business, the following products have been certified for their environmental performance:

Jet Press 750S High Speed Model:  GOLD

Effects on reduction of environmental impact:

  • Many of the consumables associated with conventional offset printing are eliminated
  • Significantly reduces the amount of wasted paper
  • Smaller footprint compared to previous models
  • The efficient drying mechanism reduces drying times, contributing to significantly higher speeds, and saving power
  • Excellent paper recycleability (de-inking ability)

Overall, there are significant reductions in resources, water use and waste compared to equivalent offset presses, with excellent paper recycling.

Revoria Press PC1120:                      SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

Revoria E1 Series:                             SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

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