Kirk Group Pushes the Boundaries of Flexo Printing with Next-Gen Plate Innovation for RollsPack
In a game-changing move for the flexible packaging industry, Australia’s Kirk Group has joined forces with XSYS and Hybrid Software to deliver a powerful flexo plate innovation tailored specifically for leading packaging producer RollsPack. The result? A cutting-edge solution that blends precision, efficiency, sustainability, and quality—setting a new benchmark for what’s possible in flexo printing.
The Power of Collaboration
This breakthrough wasn’t built in isolation. It was the product of a long-standing partnership. Kirk Group, known for its innovation-driven culture, has worked with RollsPack for over two decades. So when RollsPack came forward with a challenge—create a more cost-effective, sustainable flexo solution without compromising quality—Kirk knew exactly where to turn.
By collaborating with XSYS and Hybrid Software, and leveraging RollsPack’s deep market insight, the team developed a highly customized, best-in-class flexo plate solution that’s already producing standout results.
Smart Technology Meets High Performance
At the heart of this innovation lies a powerhouse of next-gen technologies:
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nyloflex NEF D plates – Known for high durability and the creation of flat-top dots, perfect for UV LED exposure and detailed surface screenings.
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Velvet Screening – Hybrid Software’s advanced dot removal algorithm smooths edges and elevates image quality, replacing older XM screening methods.
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Woodpecker Nano Surface Patterning – ThermoFlexX’s ultra-fine surface texturing dramatically improves ink laydown, boosts print consistency, and reduces costs.
These technologies were brought together using the ThermoFlexX imaging system and Catena+ automated plate processing line, maximizing production efficiency and ensuring seamless integration into existing workflows.
Real Results on Press
Print Manager Thanh Huynh of RollsPack reported impressive results from the collaboration:
“There’s a marked difference in ink laydown—especially on white ink base layers, where density typically drops. The results with Woodpecker are among the best I’ve seen in flexible packaging. And Velvet Screening holds the dots perfectly, delivering sharp, clean prints with fewer hard edges.”
Beyond quality, there’s sustainability. RollsPack is committed to reducing environmental impact, and this solution is helping them move away from solvent-based inks toward high-performing water-based alternatives—without sacrificing quality.
Innovation That Fits Any Workflow
Another standout feature? Flexibility. Velvet Screening and Woodpecker Nano don’t require proprietary setups or restrictive platforms. According to Brenton King, Sales Manager at Hybrid Software Australasia, “Velvet works with any resolution, on any CTP device, and on any plate. There’s no barrier to adoption.”
This kind of versatility is a big win for packaging converters looking to modernize without overhauling their entire infrastructure.
Scaling the Vision
The innovation doesn’t stop here. After installing the Catena+ line in Melbourne, Kirk Group is already expanding, with new installations planned for Brisbane and Sydney. The company’s COO, Robert Selvaggio, noted, “Catena+ tripled our plate production capacity and elevated our quality. It's a cornerstone of our strategy to deliver smarter, faster, and more sustainable flexo solutions.”
The Future of Flexo Is Here
This successful collaboration proves that flexo printing still holds immense potential—when powered by the right partnerships and technology. As Robert Selvaggio summed it up, “Flexo remains the dominant force in packaging. To stay ahead, we must maximize every opportunity through innovation and collaboration. This project with RollsPack is a perfect example of how we can achieve that.”
With Kirk Group, XSYS, and Hybrid Software leading the charge, the future of flexo printing is looking sharper, greener, and more exciting than ever.