Overview:
Sustainable Mono-Material Pouch Production for Label Expo — Powered by Durst, Cellcoat, and Galaxy.
For Label Expo, the spotlight is on agility, sustainability, and shelf-ready impact. This case study showcases a fully digital, inline production workflow for Zip Lock Pillow Pouches, combining Durst inkjet printing, Cellcoat thermal lamination, and Galaxy pouch converting – all using mono-material Enviraflex films.
- Our process begins with us designing, perfecting and agreeing on the artwork, and going through all of the test and refinery stages.
- Next, we then send the artwork to print with Durst Tau 330 RSC E – which is perfect for high-speed printing.
- The laminating is then done on the inline Cellcoat T54 that corona treats the print surface, then thermally laminates and chills the web in two steps, before preparing a neat real of stock.
- That stock is then used in the Galaxy GS24PLUS200 – for precision pouch conversion. It is a pouching line that unwinds, folds the stock and then goes through a process of heating, punching, inserting a zipper top and bottom and sealing.
- Finally, we finish our process by cutting the continuous web into nice pile of pillow pouches ready for inspection and packing.
Real-World Impact
“I visited BakPac for an hour and a half and left with 2,000 beautiful pillow pouches ready for Label Expo.”
Jonathan Smith, Cellcoat Laminating Systems
This rapid turnaround was made possible by the seamless integration of digital print, inline lamination, and pouch conversion – all optimized for quick set up, short-run, high-quality output.
Results
| Metric | Outcome |
| Production Time | 90 minutes from visit to finished pouches |
| Material Waste | Reduced by 40% vs. traditional lamination |
| Sustainability | 100% mono-material, recyclable pouch |
| Print Quality | 1200 dpi resolution with vibrant color depth |
| Seal Integrity | Excellent zip performance with no delamination |
Conclusion
This Label Expo showcase proves that speed, sustainability, and quality can coexist. The combination of Durst + Cellcoat + Galaxy + Enviraflex delivers a future-ready solution for converters and brands looking to innovate in flexible packaging.
Get In Touch!
For samples and to discuss what we can do for you, get in contact with us! Reach to us to find out how you can fit your existing equipment with inline lamination.
Get In Touch With The Team | Cellcoat Systems
Alternatively:
Email: sales@cellcoat.uk.com
Phone: +44 (0)114 269 3322
