With the global flexible packaging market valued at over US$300 billion, investment in research and development is accelerating across every region. Manufacturers are focused on creating packaging that is lightweight, durable and functional while reducing environmental impact and improving recyclability.

A Global Market Focused on Innovation

The Asia-Pacific region remains the largest market for flexible packaging, driven by rapid urbanisation, manufacturing growth and increasing consumer demand. North America continues to experience significant growth through investment in sustainable packaging solutions and e-commerce, while Europe continues to lead the way in developing packaging that supports circular economy initiatives.

Although regional priorities may differ, manufacturers worldwide face many of the same challenges: producing packaging that protects products, extends shelf life and meets increasingly demanding environmental standards.

The Importance of Barrier Performance

The primary function of flexible packaging is to protect its contents throughout transportation, storage, retail display and consumer use. For food, pharmaceutical and other sensitive products, maintaining product integrity is essential.

Barrier coatings play a critical role by protecting products against moisture, oxygen, grease, UV light and other environmental factors that can reduce shelf life or compromise quality.

Effective barrier technologies help to:

• Extend product shelf life.
• Reduce food waste.
• Prevent contamination.
• Preserve flavour, aroma and nutritional value.
• Improve product performance while supporting recyclable packaging designs.

For some products, barrier performance works in both directions. Coffee and tea packaging, for example, must not only prevent oxygen entering the pack but also retain the product’s natural aromas and flavours.

Balancing Performance with Sustainability

As sustainability becomes a central focus across the packaging industry, material selection has become increasingly complex.

Paper-based packaging is often viewed as a sustainable alternative to plastic, but achieving the required barrier performance frequently requires additional functional coatings. Materials such as EVOH can provide excellent oxygen barriers but may require further protective layers to resist moisture, adding complexity to recycling processes.

The challenge for manufacturers is to achieve the right balance between performance, processability and end-of-life recyclability without compromising product protection.

Bio-Based Coatings and Renewable Materials

One of the most exciting areas of development is the growth of bio-based and renewable coating technologies.

Materials derived from natural sources, including polysaccharides, proteins and lipids, are attracting significant interest due to their potential to deliver high-performance barrier properties while reducing environmental impact.

Research is also expanding into innovative renewable materials such as seaweed, agar and carrageenan. These formulations present unique coating challenges because of their high water content and specialised drying requirements, making pilot-scale development essential before commercial production.

From Laboratory Trials to Commercial Production

Developing new coating formulations requires equipment capable of accurately replicating production conditions while using only small quantities of material.

Pilot coating systems allow manufacturers to evaluate multiple coating methods, optimise drying parameters and validate performance before committing to full-scale manufacturing. This significantly reduces development costs, shortens project timescales and provides greater confidence when introducing new products.

The RK Print VCML Pilot Coater has become an important development platform for companies working in flexible packaging, offering a range of interchangeable coating and printing technologies including direct and reverse gravure, slot die, flexographic coating and knife-over-roll applications. Its ability to laminate using pressure-sensitive adhesives further expands its development capabilities.

Accelerating Product Development

As demand for sustainable flexible packaging continues to grow, manufacturers need development equipment that bridges the gap between laboratory research and commercial production.

Pilot coating systems enable researchers and product developers to evaluate multiple coating methods, optimise drying parameters and validate performance using minimal quantities of material. This reduces development costs, shortens project timescales and provides greater confidence when scaling up to full production.

The RK Print VCML Pilot Coater offers a range of interchangeable coating and printing technologies, including direct and reverse gravure, slot die, flexographic coating and knife-over-roll applications. Its modular design allows manufacturers to simulate commercial coating processes in a controlled laboratory environment, helping to accelerate innovation while reducing development risk.

Looking Ahead

As the flexible packaging industry continues to evolve, innovation in materials, coating technologies and manufacturing processes will remain essential. Manufacturers are increasingly seeking solutions that deliver exceptional product protection while supporting sustainability, recyclability and production efficiency.

By providing flexible pilot coating systems that accurately replicate production processes, RK Print helps manufacturers develop, refine and validate new products with confidence, enabling faster innovation and a smoother transition from laboratory development to commercial manufacture.

A Partnership That Stands the Test of Time

The relationship between RK Print and Matsuo Sangyo began after a handwritten letter was sent in response to a newspaper article featuring the RK K Hand Coater. More than 55 years later, that initial connection has grown into a trusted partnership, supporting customers across Japan with industry-leading laboratory and pilot coating solutions.

Matsuo Sangyo serves a diverse range of industries through the import, export and domestic supply of coating raw materials, high-performance functional materials, industrial equipment, optical components and automotive parts. Their technical knowledge, combined with RK Print’s equipment, enables customers to carry out accurate product development and process optimisation.

Supporting Research and Product Development

One of the key advantages of RK Print equipment is its flexibility. As Matsuo Sangyo explains:

“RK equipment plays a key role in supporting these markets. Their strengths lie in the ability to perform a wide variety of tests simply by changing the head, combined with a space-saving design and the ability to carry out accurate, efficient testing using small amounts of material.”

This versatility allows manufacturers to evaluate multiple coating techniques using a single platform, helping to reduce development time, minimise material waste and generate reliable, repeatable results.

Hands-On Demonstration Facilities

To provide customers with practical experience before investment, Matsuo Sangyo has established a dedicated RK demonstration facility in Japan featuring the VCML Pilot Coater. The facility enables customers to conduct trials using their own substrates and coating formulations, giving them confidence that processes developed in the laboratory can be successfully transferred to production.

This capability has proven particularly valuable for companies focused on sustainable product development.

A customer of Matsuo Sangyo, Dainichiseika (Japan), commented:

“With VCML, we can now produce reliable, reproducible data that matches real production environments—accelerating our sustainability-focused R&D.”

Looking Ahead

Strong distributor partnerships are fundamental to RK Print’s global success. By combining innovative equipment with local technical support, Matsuo Sangyo continues to help manufacturers across Japan improve product development, optimise coating processes and accelerate innovation.

We are proud to have worked alongside Matsuo Sangyo for more than 55 years and look forward to continuing our successful partnership for many years to come.

Working across industries including coatings, inks, printing, plastics, and materials testing, Urai supports customers throughout Italy with high-quality equipment and local expertise. 

Our relationship began in the 1970s and has grown steadily over the decades. Today, there are approximately 300 RK Print instruments installed across Italy, highlighting the strength and longevity of this partnership. 

RK Print equipment enables Urai’s customers to achieve accurate, repeatable, and reliable test results, supporting product development, quality control, and compliance with international standards. 

Through their dedicated laboratory and technical capabilities, Urai provides local demonstrations, servicing, and ongoing support, ensuring customers benefit from long-term performance and reliability. 

“Our partnership with RK Print spans several decades and is built on trust, technical excellence, and a shared commitment to supporting our customers with reliable and innovative testing solutions.”

Web tension is created by pulling or stretching a moving web against a resisting force during processing. It is entirely transient — once that force is removed, the tension no longer exists. Despite this, its influence on coating and converting performance is significant. 

The Impact of Web Tension on Coating Quality 

Many process variables affect a moving web, including ink and coating viscosity, drying temperatures, and cooling over chill rolls. However, web tension is one of the most influential factors when it comes to: 

• Coating thickness accuracy and consistency 

• Dimensional stability of the web 

• Lamination quality 

• Overall material integrity 

Without correctly applied tension, it is impossible to properly control a web. Tension is required to maintain traction between the web and both driven and idler rollers throughout the process. 

Managing Tension Across the Entire Process 

Effective web tension must be controlled within defined limits — from the unwind, through each processing zone, and right through to the rewind. Poor tension control can lead to inconsistent coating performance and reduced product quality, particularly in barrier, surface, or functional coating applications. 

When web tension is too high, the web may stretch in the machine direction and compress in the cross-machine direction. This can cause a narrowing of the web width, leading to wrinkles or instability. 

When tension is too low, the opposite can occur — shrinkage in the machine direction and widening in the cross-machine direction — again increasing the risk of wrinkling. 

Problems such as dished rolls, wrinkles, and even web breaks are often symptomatic of poor tension control at the unwind or rewind. In many cases, converters may struggle to run different substrate thicknesses or widths consistently as a result. 

Closed-Loop Tension Control and Load Cells 

One effective approach to managing web tension is the use of closed-loop load cell systems. In closed-loop control, the measured output (web tension) is continuously fed back into the control system, allowing real-time adjustment and stability. 

Load cells have no moving parts and can be integrated at key points along the web path, making them well suited to pilot-scale and production-scale coating systems. This type of control provides improved consistency and repeatability across a wide range of materials and process conditions. 

The Role of Web Guiding Systems 

Web guiding is another essential element of stable web processing. Substrates are rarely perfectly uniform in thickness or weight, and these imperfections can cause lateral web movement or drift. 

Edge and web guiding systems help keep high-speed webs accurately aligned throughout processing. Modern guiding systems are increasingly compact, easy to use, and designed for plug-and-run operation, reducing operator workload while improving precision. 

Different sensing technologies are available, including: 

• Wide-band sensors 

• Spot sensors 

• Ultrasonic sensors 

These options allow effective guiding across both transparent and opaque substrates, including light-sensitive materials. 

Supporting Development with Pilot-Scale Coating Systems 

For organisations involved in product development, innovation, or sustainability-focused research, pilot-scale coating systems provide an effective bridge between laboratory testing and production. 

Pilot coating platforms with selectable coating, printing, and laminating processes — combined with advanced tension and web control — allow users to evaluate materials and processes under realistic conditions, using limited material quantities. 

For applications requiring wider webs, heavier substrates, or bespoke configurations, pilot-to-production systems can be individually designed to incorporate high-specification drives, tension control, and guiding systems tailored to specific requirements. 

Conclusion 

Accurate web tension and effective web control are fundamental to achieving reliable, repeatable results in coating and converting processes. Whether at laboratory, pilot, or production scale, controlling these variables helps ensure coating quality, process stability, and material integrity — supporting better decision-making throughout product development. 

If you’d like to learn more about pilot-scale coating, web control, or tension management for your application, contact RK Print at sales@rkprint.com. 

Poli Instrumentos provides equipment and solutions for laboratory testing, quality control, and industrial applications, supporting customers across a wide range of sectors.

This partnership will strengthen RK Print’s presence in the Brazilian market, ensuring customers have access to local sales support, technical expertise, and RK Print’s range of coating and print testing equipment.

For further information, please contact:
info@polinstrumentos.com.br

+55 19 3876 6713
www.polinstrumentos.com.br

RK Print looks forward to building a strong and successful partnership with Poli Instrumentos.

Cromocol specialises in supplying equipment and solutions for colour management, testing, and quality control, supporting a wide range of industries across the region.

Through this partnership, customers in Scandinavia will benefit from local expertise and support, along with access to RK Print’s range of coating and print testing equipment.

For further information, please contact:
info@cromocol.se
+46 33 23 50 00
www.cromocol.se

RK Print looks forward to working closely with Cromocol and supporting customers across the Scandinavian market.

The coaters support the development of sustainable packaging materials across sectors including fibre & board, flexible packaging, tapes, labels and biobased materials.

The identical VCML systems allow results to be replicated across sites and feature multiple coating methods, lamination capability with pressure sensitive adhesives, closed-loop web tension control and hot air and infrared drying.

Their short-run flexibility enables precise evaluation of functional and barrier coatings critical to packaging performance, circularity and sustainability.

Dinakar Gnanamgari, Vice President Innovation and Portfolio Expansion, commented: “Partnering with RK Print Coat Instruments reflects our commitment to delivering reliable, scalable R&D solutions that customers can trust at production scale”.

Why We Made the Switch
Like many businesses, we faced rising operational costs, supply chain challenges, and outdated, paper-based processes. We needed an ERP system that could:

• Improve efficiencies in production and manufacturing
• Reduce reliance on manual processes
• Provide real-time business insights
• Enable cloud-based access for greater flexibility

After evaluating multiple ERP solutions, including SAP B1 and NetSuite, we found Acumatica Cloud ERP to be the perfect fit. The system’s intuitive user experience, role-based dashboards, and manufacturing-centric features stood out, making it an ideal choice for our business.

A Well-Planned & Smooth Transition
With the expert guidance of Applied Business, our transition to Acumatica was smooth and efficient. Key factors that contributed to our successful implementation included:

A phased approach to ensure minimal disruption

Process Champions within RK Print to drive internal adoption

Parallel system usage to maintain seamless operations

Our Managing Director, Andy James, emphasized the impact of this change:
“The process went very well because we invested time in planning. With Applied Business’s expertise, we identified priorities and executed the transition efficiently. Importantly, our customers were unaware of the changes happening behind the scenes, as our operations continued smoothly.”

Tangible Business Benefits
Since implementing Acumatica Cloud ERP, we have seen remarkable improvements across our operations:
Enhanced Inventory Management – Fewer stock outages and a smoother production flow
Improved Procurement Efficiency – Automated purchase orders eliminate duplication
Better Customer Service – Real-time order tracking for faster responses
Real-Time Business Insights – Data-driven decisions with role-based dashboards

Our Managing Director Andy James summed it up best:
“It’s like we’d been driving a Ford Escort for years, and now we’re behind the wheel of a Rolls Royce. I now find myself wondering how I managed to run this business before Acumatica!”

The Future with Acumatica
By embracing Acumatica Cloud ERP, RK Print is now positioned for continued growth and innovation. With a more efficient and agile system in place, we can focus on delivering high-quality solutions to our customers while adapting to the evolving business landscape.

If you’re considering an ERP transformation, we highly recommend Acumatica and the expertise of Applied Business. This journey has been a milestone in our company’s history, and we look forward to the future with confidence.

Contact Applied Business to learn how Acumatica can revolutionize your business:
01767 677071
sales@appliedbusiness.co.uk
www.appliedbusinesscloud.co.uk

At RK PrintCoat Instruments, we are pleased to announce our new partnership with The Printing Charity, further strengthening our commitment to the wellbeing and professional development of our employees. As a global leader in printing and coating technology, we recognise the importance of supporting our staff both personally and professionally.

By joining The Printing Charity, our employees will now have access to a range of valuable support services, including financial assistance, mental health resources, and career development opportunities. With over 200 years of experience supporting professionals in the printing, packaging, and publishing sectors, The Printing Charity offers confidential guidance, grants, and training to help individuals thrive.

Our Managing Director, Andy James, shared his thoughts on this initiative: “Our employees are at the heart of everything we do, and we are committed to ensuring they have access to the best possible support. By partnering with The Printing Charity, we can offer additional resources that will make a meaningful difference in their lives, whether through financial aid, mental health support, or career guidance.”

At RK PrintCoat Instruments, we continue to invest in our employees, ensuring they have the necessary tools and support to excel in their careers. This partnership is just one of the many ways we are fostering a positive workplace culture and reinforcing our position as an industry leader.

For more information about The Printing Charity, visit www.theprintingcharity.org.uk