Traditionally reliant on web-offset presses, Faller Packaging faced growing challenges in meeting customer demands for faster turnaround times, smaller batch sizes, and increased production flexibility. The company, a specialist in pharmaceutical leaflet insert production, must meet the highest standards of print quality, readability, and regulatory compliance their demanding clients expect.
Faced with these challenges, and after their existing offset press suppliers discontinued production, they sought a digital printing solution. ‘We surveyed the market for a long time to find the right digital printing technology we needed. We found SCREEN’s presses to be the best option in the digital domain. Not only do their digital presses meet the challenging safety and regulatory criteria of our pharmaceutical customers, but they also offer the top print quality we wish to provide,’ said Faller Packaging’s Director Operations Leaflets Antonio Celano.
As pharmaceutical leaflets, with their own unique set requirements and client expectations, was an uncharted application for digital inkjet, SCREEN developed a suite of advanced solutions tailored to meet the exacting demands of the pharmaceutical sector.
The primary challenge related to meeting readability and quality control expectations, necessary for medications where a single misprinted character could result in leaflets being rejected or even risking consumer safety.
To bring leaflet production into a digital future, SCREEN Truepress Ink SC+ was reformulated to reproduce crisp, high-resolution texts that pass all readability requirements. This advanced ink set delivers offset-level high-density colour and monochrome ink coverage on thin 40gsm papers that proliferate the pharmaceutical leaflet sector, without bleeding or show through.
Then to ensure leaflet integrity and traceability, SCREEN’s proprietary JetInspection systems verify every individual print, flagging any imperfections for identification with their camera systems for automatic cutting and rejection by end-to-end integrated finishing solutions.
The combination of these features allowed Faller Packaging to seamlessly integrate digital inkjet with their existing finishing equipment alongside traditional offset, enabling a smooth transition toward more flexible, short-run printing without compromising quality or compliance.
Following the deployment of their three Truepress JET presses, and approval from their pharmaceutical clients, Faller Packaging currently prints up to 50% of all their leaflets using two high-speed SCREEN Truepress JET 520HD Monos for monochrome leaflets and a Truepress JET 520HD+ for full colour printing jobs.
What sets this approach apart is that Faller Packaging does limit the use of their digital presses to short-run jobs. Instead, leveraging digital printing to handle the same range of production volumes as offset presses. ‘We’re excited about the results we can achieve,’ said Celano. ‘The SCREEN machines’ ease of use, their seamless compatibility with finishing equipment, the company’s excellent service and support and, as said, their print quality, have exceeded our expectations.’
As the team at Faller Packaging expects that inkjet will continue to gain a larger share as clients recognise its flexibility, speed, and cost-efficiency without sparing consistent quality, they’ve taken steps to expand their digital printing capabilities. ‘We’ve already signed the order for the next machine. My only concern is if one is enough to meet our growing demand for digitally printed leaflets,’ Celano concluded.
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