Combi: The Latest in Coating and Laminating Machine


    If high performance and adhesive interchangeability is important for your business’s production then look no further than the new Combi coating and laminating machine. This machine expands the variety of packing methods while maximizing output and decreasing cost and waste. The Combi meets the regulatory requirements to package microwaveable products, retort, and package fatty food applications.

    Here are some more technical details: The Combi incorporates its features for multipurpose coating and laminating to accommodate the needs of the flexible packaging converter. As an optional feature, inline coat weight measurement systems can be installed to lower waste, decrease cost and increase quality. The coat weight measurement system focuses on accuracy with the use of infrared light technology. The unit continuously displays the coating weight in g/m2 or lbs/ream; base film and ink do not affect measurement. It is a non-contact, non-destructive, on-line measurement.

    The Combi offers solvent free, solvent based, AND water based applications as well as back side cold seal coating in register for printed film with QUICK change features to switch between coating types.  To summarize, the Combi minimized quality problems, improves production efficiency, monitors production, and most importantly REDUCES COST. If you’re looking for a high performance coating and laminating machine the Combi is the machine for you.

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    Karlville’s France Technology Center Tour, Machine Demos, and Roundtable Sessions Were A Great Success!

      karlville france

      Karlville’s European Technology Center in the City of Lyon, France Hosted a Wonderful Tour!

      We here at Karlville would like to thank the hundreds of visitors we welcomed to our technology center in the city of Lyon. Our June 23rd Open House was a rousing success. We hosted roundtable introductions to our latest Sleeve innovations as well as machine demos and a facility tour.

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      Karlville’s New Miami Technology Center Opening Tour (In Pictures)

        Welcome to Karlville's new technology center in the heart of Miami!

        Welcome to Karlville’s new technology center in the heart of Miami!

        Karlville made a resounding success out of our participation in the Global Pouch Forum 2015.

        Hosting a private tour of our brand new Karlville Technology Center in the heart of Miami was a wonderful opportunity to show off our latest and greatest products and alliances. 

        We announced partnerships with LaserSharp Flex Pak, Widmann, and 3M for products that are revolutionizing the industry and the marketplace in efficient and affordable machinery that gets the job done right.

        Take a look at some of the action that our tour attendees got to be part of. It was a wonderful afternoon of business in the blaze of the Miami heat.


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        Karlville Development Group of Miami Proudly Announces Three New Strategic Global Partnerships

          Karlville VP Raul Matos showing off a new product

          Karlville VP Raul Matos showing off a new product

          Karlville Development Group of Miami is proud to announce 3 new strategic global partnerships furthering the company’s high standing in efficient manufacturing solutions that maximize customer’s profit potential. Karlville announced the partnerships throughout the tour of their new state of the art service and demo center which doubles as a contract packaging operation in the heart of Miami. Karlville President John Price and Vice President Raul Matos introduced international industry insiders to new technology at the Global Pouch Conference 2015.

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          Karlville VP Raul Matos On New Markets: “The Pouch Business is The Biggest Thing Happening in Latin America”


            Karlville Vice President Raul Matos addressing a tour group at the new state of the art Karlville Technology Center in the heart of Miami in June 2015

            Karlville is a global force in the shrink sleeve, slitting, tampering, inspection, and pouch industries.

            Since 1996, the company has established a reputation for excellence in manufacturing, efficiency, sales, service, and maintenance.

            Now we will continue our upward trajectory with a new state of the art facility in the heart of Miami, and a line of machines that are ready to take the industry by storm with affordability, efficiency, and support as the hallmarks of the company’s services. Here’s what vice president Raul Matos had to say about industry trends, growth in the market, and what puts23 Karlville ahead of the competition.

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            Karlville and LaserSharp Partner to Bring Affordable Laser Scoring Technology to the Hispanic Packaging Market

              karlville and flexpak laser partnership

              Executives from Karlville and LaserX FlexPak in the new Karlville Technology Center in the heart of Miami, Florida

              Karlville Development Group of Miami is proud to announce a new alliance with LaserSharp FlexPak Services LLC.

              This will bring laser capacity to the flexible packaging markets into the Southeast USA, Caribbean, and South American markets.

              Karlville is a leading global machinery manufacturer for the converting & packaging industries with established service and manufacturing operations in USA, Europe and Asia.

              A demonstration system consisting of a Karlville slitter-rewinder and LaserSharp® laser processing system will be installed within Karlville’s newest converting facility in Miami, FL. by November of 2015.

              This new collaboration will bring value to the packaging industry by adding laser contract manufacturing services and Laser equipment sales that will deliver rapidly integrated solutions to satisfy the increased demand for laser perforating, and scoring for flexible packaging in the region.

              The LaserSharp® equipment will be fully integrated and rapidly available for package design and testing, prototyping, laser contract manufacturing, and equipment demonstrations to offer brand owners and packaging converters multiple flexible packaging solutions using laser technology.

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              Karlville’s Safeprints Facility Tour for Shrink Sleeve Conference 2015 in Pictures


                On the bus to the Safe Prints facility – All Photos Courtesy of Karlville

                 Karlville treated the AWA Shrink Sleeve Conference to a tour of the world class facility of one of our local customers, Safeprints in Miami, Florida. The company got its moment in the spotlight as a world of manufacturers converged for networking and creating business opportunities.

                They were treated to hot food, cold drinks, and a wonderful facility tour along with guided explanations of the newest Karlville machinery for shrink sleeve converting and shrink sleeve application, pouch converting and narrow web slitting/inspection equipment.

                Excellent networking took place as visitors from Latin America, Asia, Europe, the United States and more came together for a fascinating look inside our industry. Here are some behind the scenes photos from the event.

                A short bus ride from the Hilton Miami took passengers to our world class facility in the very central location of Doral, not far from the famous Trump resort that is home to one of the finest golf courses in the nation, the famous Blue Monster at the Trump National Doral.

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                TLMI: L.I.F.E. certification for Syracuse Label & Surround Printing

                  by Narrow Web Tech

                  LIFE Registered

                  USA New York-based Syracuse Label & Surround Printing has recently become L.I.F.E. certified and that the company is the 52nd facility to achieve this certification. The program was developed in order to assist TLMI members in finding cost effective ways to reduce their companies’ environmental footprint. It is designed specifically for the narrow web marketplace and addresses four key elements of the narrow web printing and converting industry: clean production, energy and greenhouse gases, product and environmentally preferable materials, and management practices. The TLMI L.I.F.E. program is the only certification platform tailored to the specific requirements of the narrow web printing and packaging industry.

                  Syracuse Label President, Kathy Alaimo, commented on her company’s goals in pursuing the certification, “We have made the decision to pursue L.I.F.E. Certification because it validates our efforts to reduce our impact on the environment and has also resulted in financial savings associated with environmentally friendly practices. This is also a an important mean to differentiate ourselves from our competitors.”

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                  Coming Soon.. 2014 FLEX PACK TECH TOUR

                    In just a few short weeks, leaders from the narrow web flexible packaging supply chain will hold the first in a series of free seminars across the country, addressing the challenges, direction and solutions with Flexible Packaging. These companies have joined forces to share their knowledge and provide content specifically relevant to the narrow web converter. Whether you have been active in this segment for some time or just started looking into it, this is one seminar you don’t want to miss!

                    The first seminar will be held – MARCH 13 – at Fullerton College, in Fullerton CA, from 10 AM to 3 PM.

                    THE BENEFITS OF THE EVENT

                    If you are thinking about the opportunities available, the technical & mechanical challenges involved, the market direction and scope, typical applications and end use requirements, regulatory requirements and a myriad of other questions concerning this exciting and growing market segment, this seminar is for you and your team.
                    Through attending you will be provided an opportunity to meet experts from the industry who will be there to talk about the latest technology:

                    • Low migration UV inks and coatings
                    • Nitrogen inert UV curing systems
                    • Newest printing plate technology i.e. in-the-round plates
                    • Market opportunities and Flexible Packaging laminations for the narrow Web converter
                    • 4800 dpi imaging technology, digital narrow web inkjet press
                    • Converting equipment such as shrink film finishing, pouch making and offline solvent less laminators
                    • Latest printing press technology.

                    The details such as a full agenda and participants are forthcoming as well as press releases. Due to the close proximity of the Fullerton event, we are reaching out to our customers as quickly as possible to ensure they get a chance to participate in this unique training opportunity.

                    Space is limited to 150 people. Please register early!
                    LABEL & PACKAGING 

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                    Labels and Labeling- Karlville Focuses on Flexible Finishing

                      As the number of mid-web presses dedicated to flexible packaging grows, Karlville is launching new finishing systems targeting flexibles and pouch packaging markets. Danielle Jerschefske reports

                      Karlville Development Group is probably best known in the labeling industry for its shrink sleeve label seaming and application machinery and its slitting and rewinding equipment. But as label converters look to move into package printing markets with new mid-web inline presses, Karlville has developed narrower machines for the laminated flexible packaging and pouch converting sectors.

                      The global flexible packaging market is estimated to be worth around 76 billion US dollars with a five percent anticipated growth rate, while the global label market is 55 billion US dollars with growth slowing to one and two percent in mature markets. Fifty percent of flexible packaging in the US contains food, and 30 percent of this consists of pouch containers. Most of this flexible market is served by wide web converters with the narrow web industry currently contributing an insignificantly small percentage.

                      Last year Karlville opened an R&D facility in Elgin, Illinois, dedicated to laminating and pouch conversion. Label converters looking to diversify their portfolios beyond pressure sensitive label production will likely find these facilities to be a useful resource. Raul Matos, vice president at Karlville, says, ‘There are many label converters that claim to be pouch producers, but in reality they are purchasing pre-made pouch structures to be top coated and printed. We would not consider this to be sophisticated pouch business and much of the margin can be achieved simply with in-house solventless lamination capabilities.’

                      A move into flexible packaging is feasible for the label converter willing to research and invest accordingly, Matos believes. The market’s requirements differ from, and are more demanding than label manufacturing. In North and Latin America, some converters can be seen using shrink sleeve label conversion as a platform to move into flexible packaging production. A clear strategy is imperative. On a scale of difficulty from one to 10, Matos believes that shrink sleeve label production is about three, while flexible packaging is more like a seven.

                      Stakeholders align

                      The stars are coming into alignment to make mid-web packaging conversion an efficient and profitable move for a label print business. New machinery is here to manage multiple SKUs, faster turnaround and more efficient production to meet brand, retail and consumer preferences for variety and more frequent design changes.

                      Many of the narrow-web industry’s leading press manufacturers offer machines engineered for thin material conversion: a list would include Muller Martini, Xeikon, Omet, MPS, PCMC and Nuova Gidue, all of whom offer presses at widths between 20-26 inches. At Labelexpo Europe 2013 more players introduced mid-web offset, flexographic and digital offset 20-30 inch presses: Nilpeter’s MO-5; the Mark Andy Versa Max; HP Indigo 20000.  These high-end machines are intended to capture a piece of existing consumer packaging orders coming down in run length.

                      Converters will be looking for production benefits against wider web printing and converting machinery including improved uptime, rapid changeover and better profitability. This can be achieved using wider ‘label’ machinery with flexible packaging industry-specific design attributes.

                      Says Matos, ‘The potential reward requires a change in mentality. First of all, this is production of primary packaging that comes into direct contact with food. Converters must be knowledgeable about the inks and adhesives involved and layering techniques. They must have a lab to test the complex laminations made and will need to acquire FDA and American Institute of Baking (AIB) Superior Certification compliance to service the food sector in the US.’ Separate but functionally similar certifications apply in Europe.

                      At TLMI’s recent Technical Conference, chemical migration of inks and adhesives was a prominent discussion as North America’s leaders looked to educate themselves on what’s at stake. A panel including Tom Hammer of Flint Group and Catherine Nielsen, a packaging attorney, spoke frankly about the attention to detail that is required for properly producing packaging that comes into direct contact with food.


                      Lamination equipment is a ‘must’ for entering these markets with an added value proposition, and Karlville has developed a series of offline solvent and solventless laminating machines in both wide and mid-web widths via its Webcontrol partnership.

                      Offline solventless laminating offers a number of advantages including lower energy and raw materials costs and a better environmental profile. Solventless adhesive is generally applied at a lower weight and modern chemistries cure thoroughly at room temperature. Curing time too is typically shorter at around eight hours.

                      While inline lamination is an option for some of the latest mid-web packaging presses, only solvent, water-based and UV adhesives can currently be applied inline. Solventless Inline is relatively new to the market and Nuova Gidue was seen launching this technology at Labelexpo Europe. While current application systems use a traditional flexo or gravure coating head, solventless lamination requires a multiple smooth roll system with precise and consistent tension.

                      Karlville’s lamination head consists of three rollers: lamination back-up, nip and heat lamination to eliminate small dots. The entire coating head includes five rollers with three independent motor drives for the feeding roller, dosing and application. Already available in 1,000mm and 1,300mm wide options, Karlville showed its latest 800mm wide system at Labelexpo Europe. It can reach speeds up to 400m/min and can include a corona treater.

                      Pouch systems

                      Karlville’s KSG multiple format inline pouch converting machines are available in twin lane and single lane formats. For liquid packaging, machines come equipped with modules that allow for two pouch formats. Module I produces single and dual gusset shaped pouches with a front dispensing spout. Module II makes side gusset pouches with a front pour spout. Each comes with a vibratory bowl feeder and rotary spout application system.

                      For the mid-web market Karlville now offers its KSP Standup Pouch machine with half the footprint of the company’s existing machines to convert material widths up to 800mm (31in). This machine is an ideal partner for offline finishing of materials produced on the new range of mid-web presses.

                      The next step for the Karlville Group will be the introduction of pouch filling machines. The supplier specializes in catering to the needs of both packaging converters and CPG buyers or contract packagers, bridging the machinery gap between supply chain stakeholders. This strategy can be seen in its offerings for the shrink sleeve label market, and will be mimicked for flexible packaging.

                      Paint in a Pouch

                      The Association for Dressings & Sauces (ADS) named Coldec Concepts its 2012 Package of the Year Award winner. Coldec won for its Paletto Paint Mix & Shake Bag, which has possible future applications in the dressing and sauce industry, as well as potential environmental benefits. Mondi produced the bags at its Steinfeld, Germany plant, and also has the capability to produce the top spout, or NorSpoutBag, at its recently acquired location in Jackson, Missouri.

                      The Paletto Paint Mix & Shake Bag can hold up to 2.5 liters of liquid. Color is made by adding a tube of pigment to a pouch of either pastel or saturated paint. The consumer then mixes the pouch to produce the desired paint hue.

                      Sustainability: Labels vs flexibles

                      All supply chain stakeholders must closely review environmental claims surrounding flexible packaging. It is critical that Life Cycle Analysis used to support sustainability claims includes end of life recovery. While benefits can be found reducing carbon and energy emissions by shipping lighter materials, the recyclability and reuse opportunity for laminated flexible packaging is limited. On the other hand, the label industry is currently collaborating closely with value chain leaders to address label and rigid container recycling and contamination issues.

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