The Comexi Offset CI Evolution platform, commercially launched in 2015, had reached 30 sold and installed machines worldwide by 2025. The manufacturer emphasizes that this solution combines high print resolution with a 100% solvent-free process while maintaining control of operating costs. The technology is used for both flexible packaging and labels, and its development is aligned with growing requirements regarding efficiency, color stability and compliance with packaging and packaging waste regulations.
Reaching the level of 30 installations, including four recent repeat orders, two of which were completed in the last year, indicates growing market acceptance of CI offset technology in the flexible packaging segment. According to the company, this solution is particularly attractive to brand owners looking for a combination of short time-to-market, high print quality and reduced environmental impact. Users employ Offset CI Evolution presses to produce a wide range of products, from sachets and packaging laminates to shrink sleeves and wrap-around labels.
Three printing technologies in one portfolio
With the development of the Offset CI Evolution platform, Comexi is strengthening its position as a manufacturer that offers three main printing technologies in the flexible packaging segment: flexographic, offset and digital. This setup allows the company to present its solutions as complementary options selected according to the production profile and requirements of the specific converter.
The manufacturer points out that the ability to offer flexo, offset and digital printing in parallel facilitates a consultative approach toward customers, who can match the technology to job volumes, quality requirements, material structure or environmental targets. In this context, CI offset is presented as a solution that combines high print resolution with relatively low prepress costs.
Reinforcing the offset division and serving global demand
Comexi notes that offset technology is a clear and growing market trend in the flexible packaging sector. In response, the company has expanded its internal structures related to offset projects and service. The objective is to provide full support for Offset CI Evolution installations, from line commissioning to long-term technical service.
According to the manufacturer, the reinforced organization is intended to enable efficient handling of rising global demand while maintaining specialized expertise in CI offset technology. The fact that four out of 30 installations are repeat orders suggests recurring use of this technology in existing converting plants.
Applications: from flexible packaging to labels
The Offset CI Evolution technology is used in a broad range of products. In flexible packaging it covers, among others, sachets, pouches, wrapping and lidding. In the label segment it is used for shrink sleeves, wrap-around labels and in-mold labels (IML).
This application portfolio results from the combination of high resolution and registration stability with the ability to run on thin polyolefin films, which is important in the design of mono-material structures. This allows users to handle both shorter runs with frequent changeovers and larger production campaigns using the same press platform.
Automation and precision in the Evolution model
The latest version of Offset CI Evolution introduces extended automation aimed at maximizing press uptime and operational efficiency. The high level of automation is intended in particular to shorten changeover times between jobs and reduce material waste during start-up.
The manufacturer highlights several key areas of improvement:
- fast changeovers enabled by automated setting sequences, which reduce the time between jobs,
- accelerated color matching that helps reach target colors more quickly and thus lowers substrate consumption during press setup,
- maintaining stable color and accurate register throughout the production run, which is important for large volumes or jobs with high quality requirements.
The combination of these functions is intended to enable more repeatable production at lower unit cost, especially in an environment where the number of short and medium-length runs is increasing.
EB technology without VOCs and energy efficiency
Offset CI Evolution uses electron beam (EB) curing technology in which volatile organic compounds are not used. The absence of solvents in the ink and coating curing system eliminates VOC emissions and at the same time simplifies safety and transport issues for consumables.
An important element of the solution is the elimination of conventional thermal drying. The lack of heat applied to the substrate makes it possible to reduce energy consumption compared with traditional drying systems. Since materials are not exposed to high temperatures, very thin PE or PP films can be printed while maintaining stable registration and higher production speeds.
These capabilities are particularly important for recyclable mono-material structures, which increasingly result from the requirements of new packaging and packaging waste regulations, such as the PPWR (Packaging and Packaging Waste Regulation). In this respect, EB technology is a tool that supports the design of solutions compliant with circular economy requirements.
EB inks, global sourcing and prepress costs
Comexi points out that EB inks and coatings for Offset CI Evolution can be sourced from multiple suppliers worldwide. The absence of explosive solvents simplifies logistics and increases the safety of transporting these materials. In addition, the EB inks used in this technology have 100% solids content.
According to the manufacturer, this translates into lower ink consumption while achieving print quality comparable to solvent-based systems. Reducing consumption while maintaining the required coverage and color intensity has a direct impact on the operating costs of the press line.
In prepress, CI offset uses aluminum offset plates that are relatively inexpensive and recyclable. According to the company, the use of such plates makes it possible to achieve the lowest prepress costs in its machine category, which is important for both short and long production runs. This facilitates the implementation of high-quality offset printing in environments with frequent job changes and increasing requirements for customization or packaging variations.
Balancing quality, cost and environment
In its communication on Offset CI Evolution, Comexi stresses that high print quality and high production speeds can be combined with cost reduction and lower environmental impact. Solvent-free EB technology, the ability to run on very thin PE and PP films and low prepress costs form a set of parameters intended to address current demands of the flexible packaging market.
The company notes that the reinforced offset division structure and the parallel offering of flexographic, offset and digital technologies are intended to help customers gradually transition to more sustainable solutions while meeting quality and economic requirements. As a result, Comexi positions Offset CI Evolution as one of the tools supporting the transformation of the flexible packaging sector toward a lower environmental footprint.
