Modern packaging graphics face increasing demands for customization and rapid adaptation across production runs. Current systems typically require pre-printed films or separate printing lines, leading to inventory complexity and production delays. Digital measurement shows that switching between product variants can take 45-60 minutes of downtime, while pre-printed inventory ties up 15-20% of warehouse space in many facilities.

The fundamental challenge lies in integrating high-quality graphics capabilities directly into packaging lines while maintaining production speeds and ensuring consistent print quality across different packaging materials and environmental conditions.

This page brings together solutions from recent research—including bidirectional synchronized thermal printing systems, digitally printed inner layers with compensator rolls, in-line customization capabilities, and surface-embedded information techniques. These and other approaches focus on reducing changeover times and inventory requirements while maintaining production efficiency.

1. Flexible Packaging with Digitally Printed Inner Layers and Integrated Compensator Roll for Thickness Adjustment

PT INDOFOOD SUKSES MAKMUR TBK, 2024

Digital printing on the inside of flexible packaging to add unique codes, promotional content, or varying patterns on the inner layers of flexible packaging using a separate digital printing process before lamination. This involves digitally printing on the laminated film rolls before combining them in the lamination process to create the final flexible packaging. A compensator roll is added to the lamination machine to adjust for the thickness variation from the digital printing. This allows precise, customizable inner printing that can vary per package while remaining regular and safe for products.

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2. Packaging Bottles with Integrated Surface-Embedded Lettering for Product Information

HYDRO HYGIENIC COMPANY LTD, 2024

Packaging bottles with embedded letters to provide product details directly on the bottle instead of labels that can't be recycled. The letters are created using embossing, carving, laser, sandblasting, or corrosion techniques to form raised, indented, or etched letters on the bottle surface. This allows product information like ingredients, allergens, and warnings to be permanently molded into the packaging instead of added as separate labels. The embedded letters can be read easily and remain intact when the bottle is recycled.

3. Integrated Digital Printing Apparatus for High-Speed Packaging Machines with In-Line Customization Capability

TETRA LAVAL HOLDINGS & FINANCE SA, 2024

Digital printing apparatus for packaging machines that enables customization of packages without reducing production speed. The digital printing apparatus is integrated into a packaging machine for pourable products like juice. It allows printing customized content onto the packages as they are being formed and filled. This allows customization of some or all of the packages without slowing down the packaging line. The digital printing apparatus is designed to work with high-speed packaging machines and does not impact production rates. It allows customization of packages like juice cartons without needing separate customization lines.

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4. Method for Positioning Dynamic Prints on Pre-Printed Packaging Using Camera-Guided Removal and Alignment

TETRA LAVAL HOLDINGS & FINANCE, 2023

A method to accurately position dynamic prints on packaging materials like cartons, that have pre-printed static designs. The method involves using a marking station with a camera to remove the static print in specific sections and reveal the underlying packaging material. This negative of the dynamic print is then placed inside the static print. The camera detects reference geometry of the static print and the removed sections to ensure correct positioning. The camera also checks quality features like code readability. This allows accurate dynamic prints even as the packaging dimensions vary.

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5. Laser-Printable Display Material with Pigment-Infused Layer for Color Change Upon Irradiation

TOYO BOSEKI, 2023

Display materials and packaging with printing that can be done by laser. The materials have a layer that allows printing when irradiated with a laser. The printing layer contains pigments that change color when excited by laser light. The pigments can be metals like bismuth oxide. The layer thickness for visible laser printing is 5-200 microns. The pigments are mixed with other resins to form the printing layer. The mixing is done in a way to prevent segregation of the pigments during extrusion. This ensures consistent pigment distribution for uniform printing. The materials are laminated and formed into display packages using techniques like vacuum deposition to create gas barriers. The lamination and forming steps are optimized to minimize shrinkage and deformation. The packaging can have a printed logo or text that is visible through the transparent material. The laser printing is distinct from the unprinted areas due to the pigments changing

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6. Automated System for Handling and Packing Items with Vertically Stacked Preprinted Blanks

KRONES AG, 2022

A method and device for automated printing and packing of items using preprinted blanks. The system involves handling preprinted packaging blanks that are stacked upright in a magazine. A printing device removes the blanks from the magazine, transports them to the packing area, and places them around the items being packed. This allows efficient automated packing of items with customized printed packaging. The blanks are stacked upright in the magazine to save space, and are transported vertically during packing. This enables using preprinted blanks with custom graphics for automated packing of items.

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7. Laser Marking System with Lateral High-Power Lasers and Synchronized Emission for High-Speed Web Processing

TETRA LAVAL HOLDINGS AND FINANCE SA, 2021

High-speed laser marking system for packaging materials that can provide precise, high-contrast marks on moving webs at ultra-high speeds like 400 m/min without curvature. The system uses individually controllable high-power lasers arranged laterally in the web width. Each laser output can emit 60W+ power. A controller synchronizes the lasers to always hit the web at the same angle based on web speed. This prevents curvature and enables accurate ablation marks.

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8. Method for Producing Laminated Packaging with Inner Substrate Printing and Heat-Sealable Transparent Layer

TETRA LAVAL HOLDINGS & FINANCE SA, 2021

A method for producing decorative laminated packaging materials with improved visual and tactile effects compared to conventional methods. The method involves printing on the inner substrate layer before laminating the transparent outer layer. This allows deeper printing beyond the substrate without affecting the barrier layer. The printed design is then sealed between layers in the packaging process. The printing temperature is below the polymer softening point. The outermost transparent layer is heat-sealable. This allows heat-sealing the containers without damaging the printed design. The printing effects can be gloss, matte, diffraction, and tactile. The method enables customizable decoration with enhanced visual and tactile properties compared to traditional laminated packaging.

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9. Method for Forming Protective Images on Packaging Using Trace Element Patterns with Modulated Tonal Variations

Limited Liability Company "Evotek Inc.", EVOTEK INC. LIMITED LIABILITY COMPANY, 2021

Method for applying a protective image on packaging materials that allows end users to authenticate products without special tools. The method involves forming the protective image using trace elements instead of continuous lines. The image is created by generating a first set of patterns with modulated lines and curves to reproduce tonal variations. A second set of patterns with separate microstructures is generated, which are dimensionally modulated to also reproduce tonal variations. These microstructures can be stochastic or repeating with recognizable features like letters or symbols. Applying these trace element patterns directly to the packaging materials allows end users to visually confirm authenticity without additional tools or equipment.

10. Method for Multicolor Decoration Printing on Laminated Sheet Composites via Electrical Charge-Based Ink Transfer

SIG TECHNOLOGY AG, 2020

A method for printing high-quality multicolor decorations on packaging materials like laminated sheet composites used for food and drink containers. The method involves contact printing using electrical charging and discharging to transfer ink onto the composite. The printing steps are: 1) feed the composite into the printer, 2) charge the outer surface in regions, 3) contact the charged regions to the corresponding component surfaces, 4) discharge the charged regions to transfer ink, 5) repeat with higher voltages for subsequent colors. The charging/discharging allows controlled ink transfer without pressure or solvent absorption issues. The printer has multiple electrodes for each color and adjustable speeds.

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11. Metal-Based Gravure Printing System for Surface Pattern on Packaging Material

ZHEJIANG MINONG CENTURY GROUP CO LTD, 2020

Manufacturing a surface pattern of a packaging product. The surface pattern is assembled by a metal-based printing system, and the pattern is printed on the surface of the packaging material by a gravure printing process.

12. Heat Shrinkable Film with Directional Shrinkage Rates for Conforming to Squeeze Bottle Surfaces

OKURA INDUSTRY CO LTD, 2020

Heat shrinkable film for decorating squeeze bottles to provide design and labeling on the bottle itself rather than a separate label or bag. The film is heat shrunk to conform tightly to the bottle surface without distortion. It contains information about the contents, branding, etc. The film is designed with specific shrinkage rates in width and length directions to prevent peeling off during squeezing. The film also contacts the entire bottle surface, including the cap and bottom. This allows the film to be printed with features like opening perforations that are correctly positioned on the bottle. The film is applied before final sealing of the bottle.

13. Printing Method with Sensor-Based Package Position Detection and Machine-Calculated Item Alignment

ROBERT BOSCH GMBH, 2020

Printing method for accurately aligning and printing items on packages using sensors and machine intelligence. The method involves sensing the package position, calculating the item alignment based on the sensed position, and influencing the printing process accordingly. This allows precise printing on packages without relying on exact positioning. By aligning the item based on package location, the printing can be done in free areas without collisions. Sensors detect the package, machine calculates alignment, and the printer prints.

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14. Laser Marking System with Cross-Wise Arranged Individually Controlled 60W Outputs for High-Speed Web Material

TETRA LAVAL HOLDINGS & FINANCE SA, 2020

High-speed laser marking system for packaging materials like films and bags that allows precise, high-contrast marking at high speeds. The system uses lasers with individually controlled outputs arranged in the cross-wise direction. Each output has a power of at least 60W to provide robust ablation. A controller coordinates the outputs based on web speed to ensure the laser hits at the same angle. This allows high-precision, high-contrast marking on moving web material without curved ablations.

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15. Laser Marking System with Linear and Circular Transport Mechanisms for Packaging Materials

WINSTECH CO LTD, 2019

A laser marking system for packaging materials like medicine, food, and cosmetics that avoids issues with erasure, ink smearing, and quality issues compared to conventional printing methods. The system uses a linear or circular transport mechanism to move a laser marking head over the packaging material. The linear system has a feeder, linear rail, and conveyor to move the marking head left/right to mark the material. The circular system has a feeder, rotary transfer device, and ejector to grip, rotate, and eject the material while the marking head marks it. Both systems have a controller to coordinate the transport and marking. The linear system allows marking on vertical packaging, while the circular system allows marking on cylindrical items.

16. Packaging System with Graphic-Coated Element for On-Site Customizable Wrapping of Rigid Products

NWOA SRL, 2019

A packaging system for rigid products like boxes, containers, or bottles that allows on-site packaging with customizable graphics. The system has a loading area for the product, a container with a graphic-coated element inside, and a sealing mechanism. The user inserts the product, pulls out the coated element, wraps it around the product, and seals it. The system allows users to choose from different coated elements with graphics to customize the packaging on site. This provides a way for users like consumers or retailers to on-site package and customize rigid products with graphics, without specialized machines.

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17. Printing and Packaging Device with Integrated Direct-to-Material Printing and Sealing Units

GENERAL PACKER CO LTD, 2018

Printing and packaging device that can print package designs directly onto the packaging material instead of using labels. The device has a unit to print the design on the packaging bags, followed by a sealing unit to pack and seal the product inside. This eliminates the need for separate label inventory and attachment. The printing unit can accommodate multiple bags for efficient production. It has separate front and back printing devices for double-sided printing options. Prior to printing, the device can perform surface treatment of the bags to improve ink adhesion.

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18. Device and Method for Laser Marking Consumer Product Packaging Through Transparent Material

JT INTERNATIONAL SA, 2018

A method and device for marking the packaging of consumer products like cigarettes that allows marking after packaging. The method involves preparing the product, wrapping it in a transparent packaging material, and then laser marking the closed box through the packaging. This allows marking after quality checks or if some packs are rejected. The device wraps the product, bundles groups, and lasers the boxes through the packaging.

19. Dynamic Packaging Label with Printable Organic Semiconductor Layer and Selective Thermal Activation

POLITECNICO DI MILANO, 2018

A dynamic label for packaging that can change its displayed content without requiring separate displays or electronics. The label has an organic electronics layer with printable organic semiconductors, insulators, and electrodes. When heated above 100°C, the annealing process improves the electronic properties of the organic semiconductors. By selectively heating certain areas of the label, it allows changing the displayed image or text by selectively activating or deactivating the organic semiconductors in those areas. The label can be directly printed onto the packaging using compatible materials and processes. This provides a dynamic label that is fully recyclable and can be produced using existing packaging equipment without adding significant cost.

20. Laminated Retort Packaging Material with Laser-Printable White Ink Layer Containing Metal Oxide

DAI NIPPON PRINTING CO LTD, 2018

Laminated retort packaging material that can be laser printed without damaging the base film. The packaging material has a laminated structure with a base material, pattern printing layer, printing base layer, barrier layer, and sealant layer. The printing base layer is a white ink that can be printed by laser light. Only the surface of the printing base layer is used as the laser printing area, avoiding damage to the base film. This allows laser printing on the laminated packaging material with clear, visible lines. The white ink has metal oxide for discoloration when irradiated with laser light.

21. On-Site Packaging System with User-Accessible Loading and Graphic Coating Application for Rigid Products

22. Plastic Cap with Directly Printed Graphic Using Industrial Techniques

23. Adjustable Mount with Movable Marking Head for Direct Packaging Surface Printing

24. Production System with Real-Time Digital Printing of Custom Information on Moving Packaging Blanks

25. Inline Packaging Bag Printer with Vacuum Conveyor, Smoothing Device, and Corona Discharge Surface Treatment

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