Flexible packaging

Wrap around, shrink sleeve, bags, pouches, sachets, lids, or any other flexible packaging application

Today, flexible packaging is gaining grounds in the field of primary packaging, with various foil and film substrates such as polymer, paper, and aluminum foils, used in a single-layer or in multilayer structures. Developments in materials science have enabled the use of plastics with better, enhanced properties, which allow manufacturers to create unique flexible packaging solutions on an unprecedented scale.

More appealing products with longer shelf life (reducing products’ perishability and food waste), higher end use convenience (such as re-closable or re-sealable flexible pouch packaging), and improved sustainability (minimizing waste and production costs). These demands have caused the proliferation of SKUs. However flexible packaging companies must address challenges such as rising prices of raw materials, cope with rapid technological changes and sustainability challenges, in developing new products. 

Agility in data management

Being able to efficiently streamline your production within your workflow, even when technology changes, is of high importance. Due to the proliferation of SKUs, there is a need for additional processing in the procurement of materials, in purchasing and disposal procedures. The product specifications are of high importance and are changing fast, thus Overprint MIS allows for the detailed description of every unique product that is requested by each customer.

Overprint’s Core module accommodates a vast number of processes and product specifications, equipment used, intuitively following the production workflow and with ease. Extensive data can be added, i.e. ink mixing recipes and color specs, as per users’ preference, and customer-specific information can be customized. While at the same time, Overprint facilitates the integration of proprietary systems and other software into one source, making it easier to manage.

Some CPGs may order in bulk of square meters, weight, and some in numbers of packs or rolls. Overprint can handle all different units and convert according to the requirements of ordering, delivering, or invoicing – which may differ on the same product.

Control over production costs

Monitoring the cost of raw materials and utilizing reports and dashboards is crucial for flexible packaging companies to better control their production costs. Having an increased number of different substrates, with additional options for sustainable materials, food safety compliant, etc., means that there will be an even more increased number of cost estimations.

Overprint’s Cost Estimation tool efficiently gathers information from multiple sources within the system compiling a detailed job analysis document. This includes multiple parameters and cost centers such as materials, outsourcing film production, print production, and labor processes, customer-specific price lists, etc.

The cost of materials and services as well as the set-up and production times are calculated for every product to prepare an accurate customer quote. The Cost Estimation engine is also fed by Machine Learning, providing a more accurate cost estimation process than theoretical forecasting or manual estimation entries.

Following production, the user can review the Production Cost Analysis report which provides detailed costs analysis of estimated and actual production costs, allowing the comparison either per job ticket or per the overall production through Business Intelligence and Reporting.

Quality Assured

Flexible packaging companies are striving to comply with strict food & safety regulations which are continuously evolving towards more tight tolerances. Assuring quality and safety is of paramount importance.

The system incorporates Quality Control reports, validating job specifications against actual deliverables, ensuring that the final product is flawless and ready for packing and dispatching. The control and management functions for quality assurance, referring to the procedures, processes, and systems that safeguard and improve the quality of production, specifically required for food safety and eco-compliance, can be integrated.

In addition, the food and pharma sectors especially require backward traceability of the final products. Utilizing barcodes and/or RFID tags across production, allows tracing back to the sources of the product and identifying each raw material that comprises a product. Furthermore, Overprint provides the possibility to issue birth certificates and to manage the quality control individually for all materials, where this is required.

Decision-making in a fast-paced environment

A powerful Business Intelligence and Reporting module collecting data from all production processes of the print facility, delivering insights, statistics, and predefined KPIs that facilitate day-to-day business activities and decisions. Standardized industry reports are available, which provide dashboards around revenue analysis, production efficiency, and warehouse optimization. Meanwhile, a dashboard designer tool allows for custom dashboards to be created for advanced analysis on individual, departmental and corporate levels.

As the flexible packaging market grows, challenges certainly will continue to arise. The agility of Overprint in adapting to different printing processes and BEL’s experience in complex production environments make for a future-proof investment.

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