What does it do?
This is a complete software, printer and ink solution to print contract proofs onto a wide range of flexible and rigid packaging substrates, developed by German proofing specialist CGS Oris. As the name says, these are the actual production substrates rather than simulations, including flexible packaging and pouch materials, shrink films, in-mould label transfers, papers, folding boxboard and metallised board. Even metal can be printed, which after coating can be baked.
The standard system comprises CGS Oris Flex Pack proofing software plus a Mutoh ValueJet 628MP 24in roll-fed printer (to which CGS has exclusive sales rights) and the newly developed XG resin inkset, that offers extended gamuts to handle “almost 100%” of the Pantone colour set. The inks are CMYK plus orange, green and white.
Alternatively a Mutoh 1628MH 64in hybrid flatbed/roll printer can be used with the same inks; this is able to handle rigid media up to 16mm thick: the 628MP can handle smaller sheets but with a maximum thickness of 1.4mm.
When was it introduced and what are the target markets?
In its latest ‘Real Substrate’ form it was introduced on 1 July. However, this is essentially an improved version of the Flex Pack + Mutoh system introduced in 2021. This used the same software and printer, but with Mutoh’s own resin inks that have light cyan and light magenta, rather than the new set’s gamut-extending orange and green, and that only hit about 90% of Pantone colours.
According to Heiner Müller, director of packaging at CGS, the target markets are primarily packaging design and pre-press houses that want to output proofs and test dummies of new products. “The requirement for physical mock-ups is much higher in the UK than in Germany,” he says, putting it down to the number of multinationals that have UK offices.
There are already about 500 users of the earlier Mutoh-based CGS solution, and they can switch to the new orange and green XG inks after cleaning out the relevant channels. “Most work with flexo printing,” says Müller, “but there are some narrow-web labels, some offset and some gravure.”
He says that many customers had previously used the now-obsolete Kodak Approval XP4 laser pigment transfer based A2-plus digital proofing system, which was highly regarded but very expensive, or the lower priced and quite widely used 2009 Epson SP WT7900 24in inkjet-on-film proofer which is no longer made.
How does it work?
There are two main elements to the system, software and printer-ink combination. The Flex Pack software handles the simulation of print processes and also rips and drives the printer. CGS says this includes iterative 4D colour management and spot colour management, with the ability to simulate flexo, gravure or other analogue and digital processes.
It’s Windows based and doesn’t need a high-power server. It can be accessed remotely by any web browser with permissions.
The standard printer is the Mutoh 628MP, a version of the low-cost standard VJ 628 that uses multi-resin inks instead of the standard eco solvent type. The multi-resin ink is broadly similar to HP’s better-known Latex inks, and likewise is water-based with the pigments carried by heat-activated resins. Müller says that the printer resolution is high enough to even print halftones from 1-bit TIFF files, though he says even customers who said they wanted this are mostly printing contone proofs.
He admits that the drying system means the printer is relatively slow – an A3 sheet takes about 15 minutes, but the system can be left to run unattended and the proofs are dry when they emerge. The VJ 628 is a compact printer and the inks are non-toxic and odourless, so the system could fit into a design office. The 24in media width allows B2-sized proofs or longer to be handled.
The alternate Mutoh 1628MH hybrid option has a 64in width and a much larger footprint thanks to the flatbed table.
Raised-image effects such as embossing can also be simulated as a second overprint process using high-build clear UV inks on the Roland VersaUV LEF (2)-200/300 or LEC2-330s baby flatbed inkjets. Cold foil can be applied by part-curing the UV ink to leave it sticky.
Does it replace anything?
Not exactly. CGS originally developed its Flex Pack system about 10 years ago, using Roland DG VersaCAMM inkjet printers with eco-solvent inks, but needing special compatible media.
This is still available with the Roland VSi series printers (their cooler operations are better for shrink films, for instance). Its ink set includes a metallic as well as CMYKOG and white. Flex Pack can also be used with 64in Epson 8600 solvent printers.
What’s the USP?
According to Müller this is the only system for producing fully colour-accurate contract proofs and mock-ups on actual production substrates, although a digital press could in principle be its own proofer.
How easy is it to use?
Müller says if you understand colour, it’s easy. Users of the earlier Roland-based system can also switch over without retraining.
Training is offered as part of the installation, carried out by local dealers. “Typically it’s a one-day install and three days training on-site.”
How is it supported?
The UK Mutoh agent, Oris Packaging Innovations, handles printer services and will have a demo system in its Bewdley showroom. The special XR ink is supplied via CGS.
What does it cost?
A turnkey installation with the 24in Mutoh ValueJet 628MP printer costs £34,000 to £35,000. If you choose the larger 1628MH it’s about £10,000 extra.
SPECIFICATIONS
Platform Windows
Printer Mutoh 628MP (standard), Mutoh 1628MH (optional, purchased via Mutoh channel)
Max media thickness 1.3mm (628MP), 16mm (1628MH)
Max resolution 1,440dpi
Inks CGS XR multi-resin
Colours CMYK plus orange, green and white
Speed About 15 minutes per A3
Price From £34,000 with Mutoh 628MP
Contact Oris Packaging Innovations 07770 448111 www.packaging-innovations.co.uk
ALTERNATIVE
Müller says there are no alternatives in current production. The closest rival would be the old Epson SP WT7900, a 24in eco-solvent printer that included a water-based opaque white ink and could print on special films and foils.
Kodak’s Approval XP4 was probably the best digital proofer ever made, with the ability to print halftones on real packaging substrates. However, it was extremely expensive new and hasn’t been made for some years and not many are still in use. It’s also too large for office use.
Although UV-cured inkjets will work with real substrates too, Müller says that CGS’ special XG resin inks have a significantly wider gamut, are food safe and do not give a raised surface layer.
