Reproflex3: Innovating flexo printing through partnership and technology

WhatPackaging? (WP): I think you can start with Reproflex3’s office in India. 
Trevor Lowes (TL): When you look at India, it’s been quite a journey. We opened a small office in 2018 for pre-press work, and then expanded into manufacturing just weeks before the pandemic. The first two years were tough, but the team did a fantastic job keeping things going. India operates differently, and we have learned a lot from the market while bringing our decades of expertise to the table.

WP: How does Reproflex3 differentiate itself in terms of working with clients?
TL: It’s about collaboration and transparency, which is why we’re developing an online portal to give customers real-time insights into their jobs and our performance.  And also, I think the skill base and knowledge base in India is really good, and it's getting better and better.

WP: How is the implementation of Project Blue?
TL: Project Blue is a high-screening, high-technology that did extremely well in the UK. We brought that into India but found no takers because it's a costly system to implement. We took a lot of the learnings and a lot of the good stuff at Project Blue and created Vortex, which is an easier system to implement within a professional programme. 

WP: Is Vortex being marketed to entry-level and mid-level players? 
TL: I would say yes, but to clarify, Vortex now incorporates about 95% of what we achieved with Project Blue. We focus on promoting Vortex as an easier, more accessible solution for everyone, without compromising on quality. The quality is just as good, if not better. When it comes to the gold standard for flexo—whether it’s plate management, output devices, or overall process control—Vortex is absolutely up there. However, it’s important to understand that Vortex is just one component of the entire workflow. 

WP: And how does the Fixed Palette System fit into this?
TL: The Fixed Palette System is all about optimising print efficiencies. If you have multiple jobs with different spot colours, we can reduce the number of colours needed, sometimes reducing 20 colours down to 10 or fewer. This not only saves costs but also streamlines the printing process. It’s a win-win for both converters and brands. It is designed to streamline the printing process by reducing the number of spot colours required for a job. Instead of using multiple custom spot colours, the system leverages ECG to reproduce a wide range of colours using a fixed set of process inks. This approach simplifies the printing process, reduces waste, and improves efficiency.

WP: Could you elaborate on your Linear Travel Testing?
TL: That’s a key part of what we do. It’s all about data capture. We go through the full process of testing, depending on the substrates, to determine which approach works best. Many people think the fingerprint is the most critical part, but linear testing is equally important. That’s where you make the right decisions—selecting the right materials and settings. Once everything is set up, you move on to the fingerprinting. At that point, everything should be locked in.

The fingerprint should essentially be like a final job—everything should be set and ready to go. If you don’t go ahead with the linear testing, things just won’t work; and if that happens, you’re not seen as a reliable supplier. So, the more we can get this right at the first stage, the better. It’s pointless to focus solely on fingerprinting if there’s no control over the entire process. You need to measure and ensure consistency across all elements—substrate, ink, anilox specs, and more.

WP: I noticed there was a collaboration with Hybrid Software. This isn’t specific to the UK, right? Could you explain what the software is and how it helps with automation?
TL: It’s a full management system that provides total transparency. What we’ve done is taken Hybrid’s cloudflow system, essentially pulled it apart, and rebuilt it on a larger hub. At the core, it is still a Hybrid system but runs on our customisations, allowing us to incorporate more features based on our customers’ needs. Customers can see where jobs are, how we’re performing, and even track KPIs. For example, if we’re only operating at 60% efficiency on a particular task, the KPIs will highlight that. This approach fosters more of a partnership with our clients rather than just being seen as a supplier. When you’re just a supplier, it tends to be purely cost-driven. 

WP: What about augmented reality and digital connectivity in packaging? Is that something Reproflex3 is exploring?
TL: We’ve worked with Digimarc and other technologies over the years, but adoption has been slow. While it’s a fantastic concept, brands are hesitant to embrace it. It’s a bit of a mystery why, because it offers great potential for consumer engagement and data collection. But for now, we’re focusing on technologies that deliver immediate value, like Vortex and the Fixed Palette System.

WP: As you mentioned earlier, India is a cost-sensitive market. How do you balance delivering high-quality solutions while keeping costs in check?
TL: It’s a challenge, but we focus on the quality end of the market. That’s the mindset we’re working with. We don’t want to compete on price alone; we want to help clients improve their profitability. For example, with Vortex, we’ve made it affordable without compromising on quality. Sourcing materials from five different suppliers might seem cheaper initially, but it’s about the full cost and efficiency of the end product. We don’t aim to work with everyone—just a select group of clients who share our mindset. It’s also about ensuring that the final printed product is both cost-effective and efficient. 

WP: How is flexo doing in India? From what we have seen, Indian markets are dominated by Gravure at a time when the rest of the world operates on flexo. 
TL: Yes. In India, there’s a push from gravure down to flexo, and at the same time, there’s a push up from low-quality flexo to higher-quality flexo. It’s a unique dynamic. The challenge is that gravure has traditionally been seen as the premium option, and flexo has had to prove itself. But with the advancements in flexo technology, we’re now able to achieve quality levels that rival gravure. The key is education. We need to show brands and converters that flexo can deliver the same, if not better, results while being more cost-effective and sustainable. It’s about bridging that gap and helping the market understand the benefits of modern flexo printing.

WP: And in terms of profits, where would India fit in the global pie? 
TL: It's probably about 12% of our global turnover. And when it comes to improving the margins, I think that we need to help people, give them the comfort factor that we are people who can deliver jobs right first time. That's the key. You want to have a job. You go to the press, you print. The customer's happy. You get the next job.

WP: Finally, what’s next for Reproflex3 in India and globally?
TL: We’re focused on continuing to innovate and strengthen our partnerships. In India, we want to further establish ourselves as a trusted partner for high-quality flexo solutions. Globally, we’re expanding our footprint, with recent openings in New Zealand. Our goal is to bring our expertise to more markets while learning from each one to improve our offerings.