Flexographic Printing Case Study for Food Packaging

CUSTOMER SUCCESS CASE STUDY

Who Is The Customer?

Starkson Packaging is a Philippine-based packaging supplier serving leading QSR brands, FMCG companies, and regional customers with customized paper and plastic packaging solutions.

What Was The Challenge?

Frequent color variation across batches, high material waste due to unstable tension, lengthy changeover times, and inability to meet growing orders from restaurant chains, resulting in delayed shipments and customer complaints.

What Solution Was Provided?

LISHG supplied a CI flexographic printing machine with advanced tension control, automatic registration system, and quick-change anilox rollers, specifically configured for food-grade flexible packaging films and paper substrates.

What Was The Result?

After installation, Starkson achieved 25% reduction in material waste, 40% faster job changeovers, consistent color density across long runs, and on-time delivery performance improved from 78% to 96%, enabling them to win new contracts from major FMCG brands.

PROJECT SNAPSHOT

Customer Background

Starkson Packaging focuses on QSR food packaging, FMCG customized packaging, and environmentally responsible packaging solutions. They had been using an outdated press that could not keep up with quality and quantity demands.

Production Requirements

The company needed stable printing performance to support burger boxes, takeaway bags, paper cups, FMCG packaging, and customized packaging projects. They required ±0.2mm registration accuracy, ≥300m/min speed, and minimal operator intervention.

LISHG Solution

A CI flexographic printing solution with servo-driven tension system, automatic register control, and ceramic anilox rolls, optimized for flexible packaging production, color consistency, and continuous 3-shift operation.

Business Value

The cooperation improved production confidence, reduced complaint rates by 60%, and supported Starkson Packaging's expansion in domestic and Southeast Asian markets, with a projected ROI within 18 months.

01 Printing Application Compatibility

The selected printing equipment should match the packaging application, including food packaging films, paper-based materials, FMCG packaging, and sustainable packaging substrates.

A suitable machine configuration helps manufacturers maintain stable printing quality across different product categories.

02 Production Capacity Requirements

Production volume directly determines the required machine speed, automation level, and operational stability.

Packaging suppliers serving restaurant chains and FMCG brands require equipment capable of continuous industrial production.

03 Printing Quality And Control System

Modern packaging markets demand accurate color reproduction, precise registration, and consistent output quality.

Advanced control systems reduce production errors and improve customer satisfaction.

04 Long-Term Business Value

Equipment investment should consider maintenance cost, energy efficiency, production flexibility, and future expansion possibilities.

The right solution supports sustainable manufacturing growth.

Step 1

What packaging materials do you print?

Step 2

What is your required production capacity?

Step 3

How many colors and printing stations are required?

Step 4

What level of automation does your factory need?

01 Analyze Production Needs

Define materials, applications, output requirements, and future growth plans.

02 Compare Equipment Options

Evaluate machine structures, automation systems, and printing capabilities.

03 Confirm Technical Configuration

Select suitable printing width, speed, colors, and control systems.

04 Validate Supplier Capability

Review manufacturing experience, customer cases, and technical support.

05 Start Production Partnership

Complete installation, training, and long-term cooperation.

1. What were the main pain points Starkson faced before working with LISHG?

Starkson struggled with inconsistent color reproduction, frequent web breaks due to poor tension control, long changeover times (over 2 hours per job), and high scrap rates (up to 12%). These issues led to delayed deliveries and lost orders from major QSR clients.

2. How did LISHG address these production challenges?

LISHG conducted a thorough on-site assessment and recommended a CI flexographic press with closed-loop tension control, automatic register system, and quick-release sleeve technology. We also provided operator training and process optimization to maximize the new machine's capabilities.

3. What measurable improvements did Starkson achieve after installation?

Within three months, Starkson reported a 25% reduction in material waste, 40% faster job changeovers, 60% fewer customer complaints, and on-time delivery improved to 96%. They also secured two new contracts with regional FMCG brands.

4. Is this solution suitable for small to medium-sized packaging converters?

Yes. While Starkson is a mid-sized producer, LISHG offers modular configurations that can be scaled to fit different production volumes. We work with converters of all sizes to match the right level of automation and capacity.

5. What ongoing support does LISHG provide after machine delivery?

LISHG provides remote troubleshooting, spare parts supply, periodic maintenance checklists, and on-site service when needed. We also offer refresher training for new operators to ensure sustained performance.

6. How does this case relate to sustainable packaging goals?

The new press significantly reduced material waste and energy consumption per 1,000 meters printed. Additionally, it supports printing on recycled and biodegradable films, helping Starkson meet their sustainability targets and offer greener options to their customers.

CASE CONCLUSION

Application Analysis Packaging production requirement evaluation

Technical Recommendation Customized machine configuration advice

Global Support Professional overseas customer service