Two years after commissioning its first BOBST VISION CI flexographic press, Pietermaritzburg-based flexible packaging converter Flowe-Pac has added a second machine to its operation. The repeat investment follows the successful performance of the first press.

For Bruce Beswick, managing director of Beswick Machinery, repeat business is one of the clearest indicators of customer satisfaction. ‘Repeat business is always a good indicator that customers are satisfied with both the product and the after-sales service provided. We’re very pleased that the majority of our business comes from returning customers,’ he says.

‘Most of our customers own more than one BOBST CI flexo press. However, Flowe-Pac is the first company in South Africa to own more than one BOBST VISION CI,’ Bruce explains.

For Flowe-Pac managing director Anthony McCleary, the decision to invest again was straightforward. ‘The decision was driven by the success of our first BOBST VISION CI,’ he says. ‘Over the past two years, it has proven to be a reliable, high-quality machine that has helped us improve the consistency of our printing and the service we offer our customers. As a family business, we don’t invest simply to have the latest technology. Every investment has to make sense for our customers, our employees and the future of the company. Installing a second VISION CI was a natural next step for us.’

Raising the productivity bar

The latest investment comes at a time when flexible packaging converters are under pressure to produce more with fewer resources. Rising input costs, tighter margins and growing customer expectations are forcing businesses to reduce waste, shorten changeover times and maximise press utilisation.

According to Bruce, those pressures have changed the way converters evaluate capital investments. ‘Pricing pressures in the industry are nothing new, and there is little indication that this trend will ease,’ he says. ‘Older technologies have become less competitive, prompting many converters to upgrade their equipment or plan investments in more efficient solutions.’

Anthony says customers expect faster turnaround times, consistently high print quality and greater efficiency. ‘Sustainability also continues to play an increasingly important role in purchasing decisions.’

He believes continued investment is essential to maintaining the company’s competitive position. ‘Technology alone isn’t the answer, but when you combine the right equipment with experienced people and a commitment to continuous improvement, it enables you to compete more effectively. We don’t see investment as trying to be the biggest company in the market. We see it as ensuring that we remain a dependable supplier that continues to improve year after year.’

Smarter automation

One of the most significant upgrades since Flowe-Pac’s first installation has been the addition of BOBST’s patented smartGPS technology.

While the original VISION CI press was supplied with partial preparation for the system, Flowe-Pac has since upgraded the existing machine and specified the new press with full smartGPS capability. The company has also invested in a new BOBST plate mounter fully integrated with the same technology, allowing both presses to operate on a common intelligent workflow.

According to Bruce, the results have been significant. Compared with the previous smartSET and smartREG systems, smartGPS reduces setup times and substrate waste while improving register accuracy and production consistency.

‘Automated pressure and register settings already deliver impressive efficiency gains, but smartGPS provides faster job changeovers, greater consistency and less waste.’

Anthony says the technology complements improvements the company has already experienced since installing its first VISION CI. ‘Print quality has become more consistent, which is something our customers notice immediately. Changeover times have reduced, allowing us to spend more time producing and less time setting up jobs. Waste has also decreased, both in terms of cost and sustainability.’

He adds that smartGPS builds on those gains by automating much of the registration and impression setup before the job reaches the press. ‘The biggest benefit is consistency. Every improvement in efficiency allows us to respond faster and more reliably to our customers’ requirements.’

Bruce adds that automation is no longer regarded as a premium feature. ‘Solutions such as smartGPS have moved from being viewed as aspirational features to becoming essential tools. Today they’re regarded as a necessity for maintaining profitability and long-term competitiveness.’

Built for growth

Adding a second VISION CI has strengthened Flowe-Pac’s production capacity and increased the company’s flexibility. ‘It allows us to schedule work more efficiently, improve turnaround times and gives us greater resilience should demand increase,’ says Anthony. ‘The additional capacity also gives customers confidence that we can continue supporting their growth while maintaining the quality standards they expect.’

The investment aligns with Flowe-Pac’s long-term strategy of measured, sustainable expansion. ‘Our strategy has always been to invest responsibly and sustainably, building the business step by step rather than trying to grow too quickly,’ Anthony explains. ‘Every investment we make is focused on strengthening our manufacturing capability, improving efficiency and creating long-term value for our customers.’

Built for growth

Behind the latest installation is a partnership that has developed over several years.

‘Beswick Machinery and BOBST worked closely with our team throughout the planning, installation and commissioning of the machine. Their technical knowledge, professionalism and willingness to support us made the entire process smooth and gave us confidence at every stage,’ Anthony says.

‘We’d particularly like to thank the Beswick team for their commitment and hands-on support. Having experienced local specialists who understand both the equipment and our business makes a tremendous difference.’

Eds note: BOBST is represented and distributed in South Africa by Beswick Machinery.

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