Flexible packaging lines rely on specialized machinery—like form-fill-seal (FFS) machines, flow wrappers, tray sealers, and roll-to-roll systems—to package products at high speed and efficiency. However, one critical aspect often underestimated is how and where to integrate coding systems for lot numbers, expiry dates, and regulatory data.
Choosing the wrong coding solution can lead to costly misprints, frequent downtime, and non-compliance with industry standards like GS1 and Sunrise 2027. This blog explores the most common flexible packaging machines, their unique coding challenges, existing equipment pain points, and how MapleJet’s Hx Nitro and Hx Ultro Bulk Ink printers offer seamless, efficient, and scalable integration.
Common Machines in Flexible Packaging and Their Coding Needs
1. MapleJet Solutions for Vertical Form-Fill-Seal (VFFS) Coding in Small to Medium Enterprises (SME) and Large Companies
- Use case: Granular foods, snacks, powders, detergents
- Typical Coding Equipment: Continuous Inkjet (CIJ), Thermal Transfer Overprinters (TTO)
- Challenges:
- CIJ: Frequent maintenance, solvent odor, ink leaks that are unsuitable for food lines
- TTO: Ribbon breaks, long changeover times, high waste
- Overall: Small window for printing before vertical sealing; variable packaging tension; hygiene concerns
MapleJet Solution: Hx Nitro (for SME and mid-scale lines), Hx Ultro CodeMax Bulk Ink (for high-speed, high-volume lines)
Why It Works: Hx Nitro’s Thermal Inkjet (TIJ) technology delivers high-resolution, non-contact coding with zero odor and zero leakage. Unlike CIJ, it uses sealed cartridges—making it food-safe and mess-free. Its small footprint fits easily into compact VFFS housings, and Hx Manager enables quick message setup. For larger operations, Hx Ultro’s bulk ink ensures uninterrupted printing over long runs with lower cost per print. The bracket system on Hx Ultro CodeMax makes it easy to install onto VFFS machines without complex retrofitting. Rotate print function ensures the print appears within the correct window every time.
Benefits:
- Safe for food packaging—no solvent smell or airborne particles
- Maintenance-free and easy cartridge swap reduces downtime
- Seamless integration with VFFS using sensor and encoder triggers
- Scalable from SME to high-speed enterprise lines
2. MapleJet Solutions for Horizontal Form-Fill-Seal (HFFS) Coding in SMEs and Large Companies
- Use case: Candy bars, pouches, medical devices, sachets
- Typical Coding Equipment: TTO, CIJ
- Challenges:
- TTO: Ribbon changeover, waste, maintenanceCIJ: Misalignment at high speed, frequent cleaning, fluid spills
- Tight synchronization needed between machine speed and print timing
MapleJet Solution: Hx Nitro or Hx Ultro CodeMax Bulk Ink TIJ
Why It Works: Both printers offer real-time data printing using encoder/sensor triggering. TIJ’s non-contact nature eliminates friction—ideal for fragile and coated films. The Hx Ultro CodeMax is suited for high-speed operations requiring GS1 barcodes and long runs, while Hx Nitro excels in lower volume or seasonal operations.
Benefits:
- Accurate code placement at high speed
- Flexible mounting and integration options
- GS1 barcode compatibility
- Consistent print quality
3. MapleJet Solutions for Tray Sealers & Thermoformers Coding in SMEs and Large Companies
- Use case: Ready meals, meat products, pharmaceuticals
- Typical Coding Equipment: CIJ, Hot Stamp, TTO
- Challenges:
- Limited space for installation
- Condensation, heat, and washdowns can affect printer reliability
- CIJ’s solvent smell and leakage can compromise food safety
MapleJet Solution: Hx Nitro for hygienic operations; Hx Ultro + Track & Trace software for pharma applications
Why It Works: Hx Nitro is compact and operates without fumes or ink leaks. It’s ideal for food plants that undergo daily sanitation. Hx Ultro Bulk Ink offers serialization and full ERP/MES integration via a Track & Trace—meeting pharma-grade standards and track & trace mandates.
Benefits:
- Durable print under hot/cold, humid conditions
- Integration-ready with automated tray sealers
- Supports serialized coding and GS1 barcodes
- Long-lasting prints using fast-dry solvent-based ink
4. MapleJet Solutions for Label Applicators Coding in SMEs and Large Companies
- Use case: Seasonal or multilingual SKUs, pharma, cosmetics
- Typical Coding Equipment: TTO, Label printers
- Challenges:
- TTOs generate high consumable costs and waste
- Pre-printed labels are inflexible and slow down agility
MapleJet Solution: Hx Nitro TIJ and Hx Ultro Bulk Ink
Why It Works: Hx Ultro replaces label printing with direct-to-film printing. It eliminates ribbon or label waste and allows variable data (lot, expiry, branding) to be updated in real time using MapleJet’s Advanced Message Editor.
Benefits:
- Zero label inventory or ribbon waste
- Real-time print updates from ERP or production schedule
- Compact integration into existing label applicator brackets
- High-resolution graphics and text in one pass
5. MapleJet Solutions for Roll-to-Roll Printing Systems (Offline) in SMEs and Large Companies
- Use case: SME & mid-size India-based converters, contract packagers
- Typical Coding Equipment: CIJ, TTO, batch coders
- Challenges:
- Frequent downtime for ink refills or ribbon changes
- Poor adhesion on laminated films
- Difficulty in maintaining print consistency over long rolls
MapleJet Solution: Hx Nitro TIJ and Hx Ultro Bulk Ink
Why It Works: Hx Ultro offers bulk ink printing with fade-resistant output and long runtimes. Designed for flexible films, its solvent-based ink ensures adhesion and smudge-resistance. It’s ideal for offline coding, offering high throughput with reduced consumable costs.
Benefits:
- Perfect for batch prep before pouching/filling
- Minimal changeover—ideal for converters and exporters
- Suitable for laminated PET, BOPP, and aluminum foils
- Clean, no-maintenance design for dusty or semi-industrial setups
Why Traditional Coding Systems Fall Short
- CIJ: Messy, solvent-heavy, frequent maintenance
- TTO: Ribbons break, create waste, high running cost
- Labels: Expensive, environmentally wasteful, limited agility
MapleJet’s Thermal Inkjet (TIJ) Advantage:
- No solvents or fumes (Hx Nitro)
- Fade-resistant, fast-dry solvent ink (Hx Ultro Bulk Ink)
- Compact and easy to install across equipment
- Controlled via Hx Manager and Hx Console for multi-printer setups
Smarter Integration for Smarter Packaging
Coding isn’t just a compliance checkbox—it’s a strategic part of production efficiency. From VFFS lines and tray sealers to roll-to-roll systems, MapleJet’s flexible, high-speed printers adapt to any setup.
Whether you need GS1-compliant serialization or simply want to ditch expensive label systems, Hx Nitro and Hx Ultro Bulk Ink offer a cleaner, smarter, and more scalable solution to your flexible packaging line.
Need to upgrade your coding setup? Talk to MapleJet today for a customized integration plan for your flexible packaging line
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