The Architectural Synergy of Hybrid Printing Systems

A hybrid press is more than just two machines sitting next to each other it is a single, integrated platform where conventional and digital stations are synchronized through a unified control system. Typically, this involves a flexographic front end that handles the heavy lifting such as printing large areas of solid color brand colors, applying white under-bases on clear films, or laying down specialty primers. This is where the analog process shines, providing a cost-effective way to use high-pigment inks that are often expensive or difficult to run through digital heads.

Following the flexo stations, the material enters the digital inkjet module. This is where the magic of customization happens. The digital heads can apply high-resolution graphics, variable text, serialized codes, or even unique patterns to every single package without stopping the press. Finally, the material may pass through additional analog stations for embellishments like cold foiling, spot varnishing, or die-cutting. By performing all these steps in a single pass, hybrid printing for packaging eliminates the need for secondary processes, reducing lead times and minimizing the risk of damage that occurs when rolls of material are moved between different machines.

Expanding Design Horizons through Bespoke Embellishment

One of the most exciting aspects of hybrid technology is its impact on high-end packaging design. Traditionally, adding luxury finishes like foil or tactile varnish was an expensive and slow process that was only viable for premium, high-volume products. In a hybrid environment, these embellishments can be applied on the fly. For example, a wine label could feature a standard flexo-printed background, a digitally printed unique serial number, and a spot-UV varnish applied by a following analog station all in one go.

This allows designers to be much more creative with versioning. A brand can produce five different versions of a luxury chocolate box for different regional holidays, each with its own unique metallic foil pattern and personalized messaging, without the astronomical cost of five different sets of analog plates. This mass-customization is a powerful tool for brand managers who want to create a sense of exclusivity and limited edition appeal while maintaining the economies of scale provided by the flexo base. Hybrid printing effectively democratizes luxury packaging, making premium effects accessible for mid-sized runs and niche products.

Operational Excellence and Waste Reduction

From a manufacturing perspective, the move toward hybrid printing for packaging is driven by a need for extreme efficiency. The packaging industry is seeing a trend toward shorter run lengths but a higher frequency of orders. In a purely analog shop, the time and material waste involved in changing over between different designs can consume a huge portion of the day’s profit. Every new plate change means stopping the press, washing up, and running hundreds of meters of setup waste to get the color and registration right.

Hybrid systems mitigate this by keeping the static elements of the design in the flexo stations while changing the dynamic elements digitally. This means that for a product line with ten different flavors, the brand’s main logo and background color the flexo part stay the same, while the flavor name and product image the digital part change instantly. The press doesn’t have to stop, and there is zero waste between versions. This versioning without downtime is the ultimate goal of the modern print shop, allowing for a much higher throughput and a significantly more sustainable production model.

Solving the Total Cost of Print Equation

When evaluating printing technologies, manufacturers often look at the cross-over point the run length where digital becomes more expensive than analog. Hybrid printing changes this calculation entirely. By offloading the high-volume, low-cost parts of the job to the flexo stations, the digital portion of the cost is localized only to where it provides the most value. This pushes the cross-over point much higher, making hybrid systems economically viable for a vast range of jobs that were previously stuck in the middle too large for pure digital but too complex for pure analog.

Furthermore, hybrid printing for packaging reduces the need for large inventories of finished goods. Because the turnaround time is so fast, brands can adopt a just-in-time approach to their packaging. Instead of ordering 100,000 labels and storing them in a warehouse for six months, they can order 10,000 labels every two weeks. This frees up capital, reduces the risk of obsolete stock, and ensures that the information on the package such as Use By dates or regulatory warnings is always current. In a volatile global economy, this agility is a critical competitive advantage.

The Technical Challenge of Color and Ink Integration

The primary technical hurdle in hybrid printing is ensuring that the flexo inks and the digital inks play well together. They are different chemistries flexo inks are often water or solvent-based, while digital inks are usually UV-curable. Achieving a perfect color match between a flexo-printed logo and a digitally-printed product image requires highly sophisticated color management software. The system must be able to translate the brand’s signature colors across these two different processes to ensure a seamless visual result.

Additionally, the trapping and registration between the analog and digital sections must be perfect. Modern hybrid presses use high-speed cameras and closed-loop control systems that monitor the output in real-time. If the digital image drifts by even a hair’s breadth from the flexo-printed border, the system detects it and makes an instant correction. This level of technical integration is what allows hybrid printing to deliver quality that is often superior to either process alone. The result is a sharp, vibrant, and incredibly consistent package that meets the highest standards of global brands.

The Future: AI and the Autonomous Hybrid Press

Looking ahead, the next evolution of hybrid printing for packaging will be driven by artificial intelligence. We are moving toward a future where the press can self-optimize. Imagine a machine that can look at a digital file, analyze the current inventory of inks and plates, and automatically decide the most efficient way to divide the job between the analog and digital stations. AI will also play a massive role in predictive maintenance, ensuring that the complex digital printheads are always in peak condition.

As the technology continues to mature, we will see hybrid capabilities expanding into new areas, such as corrugated board and flexible films. The hybridization of the industry is a reflection of a wider cultural shift toward personalization and speed. In a world where consumers expect products to be tailored to their specific needs and delivered almost instantly, the rigid, siloed manufacturing models of the past are no longer sufficient. Hybrid printing is the flexible, intelligent answer to the challenges of the 21st-century marketplace.

A New Era for Packaging Innovation

The impact of hybrid technologies extends far beyond the production floor it is a catalyst for innovation across the entire value chain. It allows designers to dream bigger, brand managers to move faster, and manufacturers to operate more sustainably. By breaking down the barriers between analog and digital, the industry is creating a new language of packaging one that is as dynamic and diverse as the consumers it serves.

Hybrid printing for packaging is more than just a new type of press it is a new way of thinking about the relationship between a product and its container. It acknowledges that in the modern world, every package is a piece of data, a marketing touchpoint, and a protective shell, all at once. The ability to manage these diverse roles with a single, integrated technology is the defining achievement of modern print engineering. The future of packaging is hybrid, and it is more creative, efficient, and responsive than ever before.

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The move indeed affects the secondary packaging, which is used throughout the US confectionery portfolio of pladis, which also includes the well-known supermarket brands like McVitie’s, Demet’s Turtles, and Flipz. This move marks a practical step toward circular packaging while at the same time maintaining shelf performance along with production efficiency.

The new pre-made block bottom bags are going to be paper-based and will be designed for recyclability in the established recycling streams. They had been developed in sync with circular design guidelines and also tested in order to meet operational as well as visual needs in terms of high-volume confectionery lines.

As per the companies, one of the major challenges that has been addressed was that of fibre cracking within the side gusset areas, which apparently is a common issue with paper packaging formats. The redesigned structure enhances the strength and look, hence helping the bags to retain their shape as well as the print quality through transport, handling, and of course, shelf display.

From the viewpoint of retail, the packaging goes on to offer an upright stability, consistent branding, and dependable sealing, while also remaining compatible with the present packing lines. This combination enables the brands to enhance the sustainability credentials without causing any sort of disruption in the supply chains or, even for that matter, altering the on-shelf presentation.

This switch also puts light on a much wider shift among the packaged food brands in the supermarkets wherein packaging recyclability is increasingly treated as a baseline need and not a differentiator. It is well to be noted that confectionery suppliers are under constant and growing pressure to sync along with retailer anticipations when it comes to waste reduction, material choice, and circularity.

The change also goes on to support wider supermarket sustainability strategies as the grocery retailers continue to tighten the packaging benchmarks throughout branded as well as private label ranges. Recyclable paper-based packaging formats, which go on to meet recyclability criteria while at the same time maintaining product protection, are indeed becoming a preferred choice across multiple grocery categories.

When it comes to Coveris, the partnership also strengthens its position of being a packaging supplier that is capable of rolling out paper alternatives at a commercial scale. For pladis, it also shows how branded manufacturers are going ahead and adapting packaging formats in response to the retailer needs, consumer anticipations, and also long-term sustainability objectives.

The companies went on to indicate that further development work is still taking place, with next-generation formats already under assessment as part of longer-term packaging roadmaps.

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The broader offering is intended to give food manufacturers and retailers a more complete set of packaging options that support shelf visibility, align with stricter EU rules, meet sustainability objectives and work across a range of product categories.

By bringing corrugated and solid board formats into its existing flexible packaging line-up, Mondi is presenting a more integrated suite of fibre-based solutions. The expansion is aimed at rising demand for lightweight designs, smaller portions, retail-ready packaging and materials with improved recyclability. The company positions the move as a response to evolving consumer behaviour and the European Union’s requirements for packaging circularity and eco-design compliance.

The food packaging range spans ventilated trays, stackable boxes, leakproof structures, shelf-ready display formats, multipacks and e-commerce-ready solutions used in online grocery fulfilment. Targeted product segments include fresh produce, meat, poultry, seafood, dairy, frozen items, snacks, confectionery and beverages. Mondi states that all packaging formats are designed to be fully renewable or recyclable in line with EU directives such as the Packaging and Packaging Waste Regulation.

Integrating Schumacher Packaging’s operations has broadened Mondi’s European manufacturing reach, adding production sites and boosting regional supply capacity. This expanded footprint is supported by the company’s accredited food safety and performance laboratories, as well as its ThinkBox innovation centres, where Mondi works directly with customers on structural design, material optimisation and processing enhancements.

Mondi Corrugated Solutions chief operating officer Paulus Goëss said: “The food sector is undergoing rapid change, with sustainability targets, EU legislation and shifting consumer behaviours all driving new requirements for packaging. By expanding our portfolio, we can help customers respond to these trends with solutions that are lighter, more sustainable and optimised for shelf appeal.”

In October 2025, Mondi introduced a redesigned banana box produced with 40% recycled fibre and up to 10% less weight than conventional alternatives, while still delivering required performance. The design resulted from a collaboration between Mondi, Ecuadorian banana exporter Incarpalm, trading partner Europcell and a European importer.

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The newly developed Cadbury Heroes paper tubs, created in collaboration with DS Smith after several years of research and development, will for the first time include the iconic Cadbury Flake. Consumers taking part in the trial are encouraged to provide feedback by scanning a QR code located inside the lid. This feedback will help guide future choices for the Heroes assortment and other packaging plans. The tubs also carry OPRL labelling so consumers can easily see how to recycle them.

This launch follows a previous collaboration between Mondelēz and Tesco, which tested approximately 1.8 million Cadbury Crunchie multipacks with 60% less outer plastic per pack compared to standard multipack formats, enabled by an innovative sticker solution.

Joanna Dias, UK Sustainability Lead at Mondelēz International, said: “We are extremely proud to announce the new Cadbury Heroes paper tubs and are excited to hear consumer feedback on the new packaging. The paper tubs demonstrate once more Mondelēz’s commitment to driving sustainable packaging solutions and this test and learn initiative in partnership with Tesco will help inform our long-term efforts to reduce virgin plastic.”

James Bull, Head of Packaging at Tesco, added: “We are delighted to be working with Mondelēz International on another sustainable packaging initiative which will support our mission to eliminate preventable packaging waste. As part of its Planet Plan, Tesco is committed to reducing its packaging footprint and collaborating with suppliers to evaluate packaging suitability.”

Paul Clarke, Managing Director for UK & Ireland at DS Smith, commented: “This project showcases our close collaboration with Mondelēz International to deliver more innovative packaging in response to growing consumer demand for sustainable solutions that make a positive impact. It demonstrates how we can design out waste without compromising on quality or design — from the rounded corners for enhanced shelf appeal, and high-quality print that supports standout branding.”

The paper tubs trial aligns with Mondelēz’s global “Pack Light and Right” strategy, focused on reducing packaging, designing for recyclability, using recycled materials where possible, and enhancing recycling infrastructure. Last year, approximately 300 million Cadbury sharing bars in the UK and Ireland were wrapped in 80% certified recycled plastic, amounting to 600 tonnes of post-consumer recycled plastic annually. Paper-based multipack bags for Cadbury biscuits have also cut about 145 tonnes of virgin plastic.

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The collaboration mixes UPM Solide™ Lucent 45 g/m² barrier base paper with EvoPak’s RCM coating to achieve a fiber-based solution that bears the protection required by the chocolate and other demanding food products. Better grease and oxygen barrier properties of this paper based recyclable packaging are expected to offer Walkers Chocolate better product quality standards. 

Since January 2024, Walkers Chocolates has been providing its manufacturing and retail partners with paper based recyclable packaging. The business has rolled this out across a number of its own products, now stocked across major UK retailers and in key international markets. 

UPM Solide Lucent is known for being a robust and highly adaptable barrier base paper. Its distinctive appearance, smooth surface, and dense structure give it strong advantages for converting processes and printing applications.

“The printability of UPM Solide Lucent is really impressive and EvoPak’s RCM coating is a revolutionary solution for our industry,” commented Tom Murtagh, Commercial Director, Walkers Chocolates. “We’ve achieved the same packaging line efficiency, maintaining the same speed as our previous plastic packaging materials with only minor adjustments.”

The combined performance of UPM Solide Lucent and EvoPak’s RCM coating, which uses a unique water-soluble polymer, has enabled the creation of a breakthrough recyclable paper packaging solution. This innovation holds the same functional advantages of traditional plastic materials but presents a fiber-based alternative to meet the targets of sustainability.

“We’re extremely happy with how the paper extrudes and the print quality in flexo is exceptional,” said Tom Lock, CEO, EvoPak. “We are 100% happy in UPM Solide Lucent as the grade of choice for our future sustainable packaging development.”

The recyclable packaging solution is fully compatible with existing fiber recycling infrastructure and also supports the circular economy. Notably, the UPM and EvoPak innovation has achieved the CEPI/4EG Technical Recyclability Score.

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Market Overview 

Today, packaging is more than a matter of holding product. It is an important operation that ensures food safety, shelf life, product presentation, and compliance with regulations. The equipment market for food packaging is a driving force that enables manufacturers to meet growing needs for convenience, hygiene, sustainability, and traceability.

By 2024, the market stood at USD 21.42 billion. It crossed USD 22.58 billion in 2025, driven by demand for cleaner, smarter, and more flexible packaging systems—specifically in Europe and Asia Pacific.

Regional Landscape

Asia Pacific was the global food packaging equipment market leader in 2024 with a share of 38%. The region is driven by growth in urbanisation, increased disposable incomes, and demand for processed and ready-to-eat foods, particularly among Gen Z consumers. The region’s potential is also driven by demand for automation, with China emerging as an innovation and production hub for high-end packaging machinery.

China’s massive investments in research and development have yielded sophisticated equipment targeted at the dairy, meat, and ready-meal packaging, while Japan is renowned for its high-speed, space-saving equipment ideal for bakery and convenience foods. These countries form part of the leading region in unison.

Europe will most likely be the fastest-evolving market. Europe’s growth is driven significantly by its adoption of AI, machine learning, and robotics within packaging operations. Markets in Europe are extremely sensitive to sustainability requirements, utilising packaging technologies favouring environmental goals and reducing carbon footprints. Germany is specifically noted for adopting sustainable systems and reaching efficiency levels across the industry.

Market Drivers

The food packaging equipment market is being shaped by some converging trends:

Growing demand for processed and ready-to-consume meals: Busy lifestyles and convenience culture keep driving demand among every age group, and Gen Z has emerged as an assertive consumer generation.

Emergence of online food delivery platforms: This has triggered a related surge in demand for heavy-duty, clean, and transport-friendly packaging solutions.

Sustainability challenges: Producers are embracing greener packaging systems that meet green criteria and assist them in meeting their ESG objectives.

Intelligent packaging solutions: Greater transparency with track-and-trace technologies and digital packaging techniques is becoming a dominant differentiator of consumer trust and regulatory adherence.

Role of Technology and Automation

The growing contribution of artificial intelligence and automation is transforming the food packaging equipment market. With solutions that utilise AI, it is now feasible to detect sub-millimetre defects in packages, in addition to improving machine performance and reducing waste. Systems of real-time monitoring and predictive maintenance also make operational efficiency and cost control simpler.

These technologies also facilitate next-generation packaging innovations such as recyclable forms, QR code coding, and smart sealing systems—all of which enhance both product integrity and sustainability.

Equipment Segmentation

In 2024, the form-fill-seal machines segment led the market for equipment with the largest CAGR. Its dominance is driven by increased demand for flexible packaging forms such as containers, pouches, and bags. They ensure quick packaging operations with high levels of hygiene and increased shelf life of products.

The filling and dosing equipment segment is expected to expand the fastest up to 2034. With customers looking for compact and accurately packaged food and beverage products, demand for these systems remains on an upward swing, particularly for outdoor and on-the-go applications. 

Application Segmentation

Of the application areas, bakery and confectionery held the largest share in the market in 2024. Packaged bakery goods—i.e., pastries, muffins, and cookies individually wrapped—have gained growing popularity, leading producers to invest in high-speed, sanitary equipment that have longer shelf lives and ensure faster distribution.

Conversely, the dairy segment shall also see the most growth over the next decade. Dairy items require machinery that offers contamination-free zones and longer freshness life and hence becomes a priority segment to invest and innovate in.

Trends Shaping the Future

• Advanced vision systems and sensors: These technologies improve quality assurance and detect flaws invisible to the human eye.
• Smart and traceable packaging: Consumers care more about transparency in supply chains, and digital traceability technology is how companies are delivering on the promise.
• Materials that are renewable: Manufacturers are having to retrofit equipment to handle recyclable and biodegradable packs due to consumers and pollution policy.
• Growth in online food retail: As people purchase food online increasingly, the need for packaging systems that will not let food down during transportation and last longer increases proportionally.

Opportunities and Outlook

Technological advancement is creating numerous opportunities for the industry. Sophisticated design competence, sustainable solutions, and smart packaging are now a competitive core element. Companies embracing digital transformation in packaging companies are best placed to grow cost-effectively and fulfil consumers with changing wants.

From emerging economies to developed markets, expanding demand for automation and green packaging is setting the tone for long-term market expansion. Although Asia Pacific continues to hold ground and Europe gathers steam, global industry stakeholders need to align strategies accordingly.

Conclusion

The equipment industry for food packaging is on a revolutionary growth trajectory that will expand to USD 36.24 billion in 2034, growing at a CAGR of 5.40% from 2025. The industry is characterised by technological innovation, sustainability-orientated overhauls, and evolving consumption patterns. Equipment suppliers and food processors alike are also investing in intelligent systems that ensure security, optimise efficiency, and match growing environmental and regulatory demands.

As automation, smart packaging, and AI join the ranks as industry mainstream, the next decade will draw a different path in food packaging—a future where speed, safety, and sustainability come together at scale.

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The pantry jars are widely recyclable and available in three sizes: 60, 81, and 87 ounces. This transition to 100% recycled plastic includes mechanically processed recycled content and will eliminate over 1,300 metric tonnes of virgin plastic per year—equivalent to the weight of around 238 African elephants.

The jars were composed of post-consumer resin, which is a packaging solution manufactured from recycled plastics gathered from consumers. This solution prevents plastic trash from ending up in landfills, minimises virgin plastic use, and lowers emissions while supporting a circular economy. For example, once these pantry jars are empty of sweets, a consumer can reattach the lid and leave it in a recycling bin; the plastic can then be used to create other products.

Berry’s production facility produces the easy-grip square jars with certified food-grade mechanically recycled resin from curbside collection streams. Berry teamed with Mars to develop a solution that would advance their joint sustainability goals while maintaining product quality.

“As companies across the globe commit to transitioning to a circular economy, the ability to deliver products made with recycled materials at scale is crucial,” said Peter Goshorn, Vice President of Food, Beverage & Spirits for Berry Global’s Consumer Packaging North America Division. “That’s why we’re collaborating with leading brands, like Mars, to significantly increase the use of recycled content to drive responsible business growth without compromising performance or aesthetics.”

As part of its Sustainable Packaging Plan, Mars is rethinking its packaging portfolio to eliminate plastic packaging and make it reusable, recyclable, or compostable. Mars has collaborated with Berry since 2017 to develop sustainable packaging.

“In the world we want tomorrow, no packaging becomes waste, but is instead reused, recycled or composted,” said Allison Lin, Global Vice President of Packaging Sustainability at Mars. “That’s why we continue to rethink our approach to packaging and collaborate with companies like Berry. Reducing our virgin plastic usage by investing in recycled content is an important step in our strategy, alongside initiatives to remove unnecessary packaging, explore reuse models and redesign our packaging for circularity. Using recycled content incentivizes increased collection systems and recycling infrastructure, which is essential for a circular economy.”

Mars is revamping 12,000 packaging components and pushing the boundaries of packaging innovation thanks to the collaborative efforts of hundreds of Mars Associates and partnerships with organisations such as Berry.

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A recent report by the U.S. Department of Homeland Security (DHS) cited research from the Organisation for Economic Co-operation and Development (OECD) showing that the value of counterfeit goods traded internationally has increased by 154 percent between 2005 and 2016, from $200 billion to $509 billion. Globalization and ecommerce have made a nearly infinite variety of goods and services available at the click of a mouse. At the same time, bad actors are becoming more sophisticated. It’s estimated that by 2022, counterfeit goods will displace more than $1 trillion in global sales from legitimate companies.

Fast and reliable authentication of genuine products is essential to safeguarding critical revenue, preventing brand identity erosion, protecting public health and safety, and maintaining consumer confidence. SICPA’s new security labels utilize innovative technology to effectively capture consumers’ attention and can be customized to promote specific symbols or brand names supporting an array of designs, colors, and visual effects.

Delivered in the form of a unique product security label, SICPA’s new solution empowers consumers, businesses, and government officials to easily and reliably validate authentic goods and products – critical to protecting against counterfeiting and fraud. The integrated product security labels can include tamper-evidence, secure 2D codes, as well as other overt, covert and forensic security features offered by SICPA. Brand owners benefit from multi-layered security features to support consumer engagement, supply chain controls and investigation and enforcement efforts.

“Produced using propriety technologies and SICPA’s fully controlled supply chain, this new solution provides business and governments both unrivaled security features and unique customization opportunities,” says Karen Gardner. “Taken together, this allows customers to not only achieve optimum brand and product protection, but also to leverage a unique marketing opportunity – creating a unique, counterfeit-resistant marking that makes it easy for consumers to identify authentic products.”

The integrated product security labels can be used effectively to authenticate pharmaceuticals, electronic and automotive components, apparel, food and spirits, and other high-end consumer products, and come supported by SICPA’s decades of experience providing security solutions for high risk and high-value products worldwide.

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“We have recently broadened our portfolio to include transparent papers and papers for applications requiring great print quality, allowing brand owners even more inventive options to consider if they are looking to reduce their use of plastic and enhance the overall customer experience.”

Based in Helsinki, Finland, Ahlstrom-Munksjö manufactures speciality papers for bakery, fast food, cheese, sweets, microwave popcorn, fruits and vegetables, and pet food markets.

The Delicitera portfolio includes Cristal transparent papers, Rocalonde twisting papers, and Gerstarpapers for glossy print applications.

Ahlstrom-Munksjö also offers release liners, decor papers, abrasive and tape backings, and electrotechnical paper.

Earlier this month, Ahlstrom-Munksjö, announced the development of a new range of LamiBak release base papers approved by the German Federal Institute for Risk Assessment (BfR).

Murphy added: “We truly collaborate with package designers, converters and brand owners to produce innovative and sustainable packaging systems that satisfy any unique requirements with the ultimate goal of delivering enhanced performance while streamlining your manufacturing processes.”

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‘Keep confectionery moving’

As Ammeraal Beltech’s Global Food Industry Segment Manager, Giuseppe Allais, comments: ‘We offer a wide choice of application-specific belts that are keeping confectionery safely moving around the world. Good examples are our non-stick, low-friction PTFE, silicone-coated belts which work happily at all temperatures between -70 C° and up to 260 C°; and our soft-lip UltraScraper, which is metal detectable, will keep your belts clean. And then there are our Ropanyl® cooling tunnel processing belts – ideal for chocolate tempering – and the recently-introduced Soliflex PRO mini — a versatile food belting solution which combines an optimal hygiene level with reduced overall costs of ownership.’

Meet the experts at ProSweets

Giuseppe Allais is looking forward to discussing visitors’ needs and wants on the Ammeraal Beltech stand at ProSweets. ‘As well as providing the standard products from our “One-Stop Belt Shop”, we are happy to design and manufacture custom-made synthetic food-grade belts to cover every specialist requirement,’ he says. ‘They can convey your smallest, lightest chocolates as well as your heaviest trays. Of course, our belting solutions are also designed to meet your HACCP programmes and comply with all the main international food standards.’

Ammeraal Beltech’s participation once again in ProSweets is a commitment to a continuing in-depth focus on food conveyor belting, and an opportunity for confectioners and snack product manufacturers to view the choices offered for their needs.

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