Circular Economy Requires More Than Recycling: A Flexographic Perspective

Dr. Dieter Niederstadt of Asahi Photoproducts highlighted the evolving role of flexographic printing in achieving a circular economy during the Next-Generation Sustainable Flexo Symposium. While increasing recycled content is a primary goal, the industry must ensure that new substrates like PCR-based films and mono-materials remain functional, printable, and commercially viable. This shift is critical for the packaging sector as it balances ambitious sustainability targets with the need for high-quality brand presentation and shelf appeal.

The transition toward a circular economy is introducing complex challenges for the packaging industry, particularly regarding the use of post-consumer recycled (PCR) content and mono-material structures. According to Dr. Dieter Niederstadt, Technical Marketing Manager at Asahi Photoproducts, materials such as PCR-PE films and thin MDO structures often exhibit different mechanical properties, including increased haze, higher flexibility, and inconsistent surface characteristics. These variations can complicate the printing process, making it difficult to maintain the stable register and high print quality required for premium consumer packaging.

Flexographic printing is emerging as a vital enabler for these sustainable materials, particularly when utilizing central impression configurations that are well-suited for handling thin or demanding filmic substrates. At the recent Next-Generation Sustainable Flexo Symposium, industry experts observed that high-quality print results are now achievable even on substrates containing more than 90% PCR content. This development is significant because it allows brand owners to meet the recycled content mandates of the Packaging and Packaging Waste Regulation (PPWR) without compromising the visual impact or functional integrity of their packaging.

The industry's focus is shifting from simple recycling percentages to a more integrated approach where material science, printing technology, and process expertise converge. Dr. Niederstadt emphasizes that a package is only truly circular if it can be processed efficiently through the entire value chain while still protecting the product and communicating brand value. Asahi Photoproducts suggests that the future of the sector depends on optimizing how new materials behave during printing and converting, ensuring that lightweight and highly recyclable designs can compete with conventional laminated structures in the global market.