Printing sustainable, flexible food packaging: how do you make it happen?

If you're in the food industry, you're likely aware of the growing pressure to reduce plastic packaging. On average, every EU resident generates 36.1 kg of plastic packaging waste annually—an increase of nearly 30% since 2010. In response, European regulations are tightening, and consumers are demanding sustainable alternatives on supermarket shelves.

For food manufacturers and packaging professionals, this shift presents both a challenge and an opportunity. The good news? Transitioning to sustainable, paper-based flexible packaging is easier than you might think with Xeikon’s cutting-edge digital printing technology.

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High-tech alternatives for plastic packaging

As someone in the packaging industry, you know the pressure is on to reduce plastic waste. Across the globe, manufacturers are actively searching for sustainable alternatives—materials that not only provide the necessary food-safe barriers but also meet EU recycling regulations.

For many, the solution lies in moving away from complex, multi-layer plastics and toward recyclable options. Mono-material plastic packaging, which uses a single type of plastic instead of a mix, makes recycling far more efficient. But the real game-changer? Paper-based flexible packaging, which is rapidly gaining traction as the industry’s most promising alternative.

With the TX500, printing on these innovative materials is seamless, giving you the flexibility to stay ahead of the curve while meeting sustainability demands.

Unlike traditional inkjet and solvent-based printing technologies, the TX500 supports both paper-based and monomaterial plastic packaging, making it one of the most versatile digital printing solutions available. While competitors require extra layers to print on paper, Xeikon allows for direct printing—resulting in better recyclability and fewer processing steps.

The rise of paper-based, flexible packaging

As sustainability becomes a priority, more food manufacturers are turning to paper-based flexible packaging. Consumers perceive paper and paperboard as the most eco-friendly choice—but as you know, packaging isn’t just about sustainability; it’s about protecting your product. The challenge? Paper alone doesn’t provide the necessary barrier to keep food fresh, and while laminating helps, it can complicate recycling.

This creates a delicate balance between shelf life and sustainability. The good news? Advances in packaging technology are bridging this gap, making it easier to meet both demands. Right now, paper-based flexible packaging is leading the way in the food industry—offering both brand appeal and a forward-thinking approach to sustainability.

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Choosing the right sustainable printing technology

If you and your clients are exploring sustainable, paper-based flexible food packaging, one crucial question remains: which printing technology is best suited for the job? With multiple options on the market, choosing the right solution can make all the difference in efficiency, cost, and compliance.

The Xeikon TX500 offers a streamlined, cost-effective approach. Unlike other solutions, it requires a lower initial investment and a smaller installation footprint. Plus, its simplified printing process reduces manufacturing steps while maximizing overall equipment effectiveness (OEE).

Unlike competitors, which require multiple production steps—including priming, printing, laminating, and drying—the Xeikon TX500 streamlines the process into a single-step workflow. This means you can go from raw material to finished pouch in just one day, significantly reducing costs, waste, and lead times.

Many printing technologies demand an additional functional barrier—such as varnish or laminates—to ensure food-safe packaging. The TX500, powered by TITON technology, eliminates that extra step. No additional barriers, no extended drying times—just a seamless, efficient process that takes you straight from printing to pouch converting.

Choosing the right toner technology

When it comes to durability and food safety, TITON toner sets a new standard. Designed to withstand scratches, water, sunlight, and chemicals, it removes the need for additional protective layers like thermal coatings or PE barriers—simplifying your packaging process while ensuring long-lasting results.

But durability isn’t the only advantage. TITON toner is completely odorless and tasteless, preserving the integrity of your product and enhancing the customer experience. Its heat resistance also makes it ideal for secure, reliable heat sealing. Offering the toughness of UV inkjet combined with the proven food safety of dry toner systems, TITON bridges the gap between performance and compliance.

Unlike UV inkjet, which contains photo-initiators, TITON toner is fully food-safe and pre-approved for indirect food contact. While competitors require an additional functional barrier to ensure compliance, TITON eliminates this extra step—providing a more sustainable and cost-effective solution.

What truly sets TITON apart? It contains virtually no PFAS, making it one of the safest choices on the market. Perfect for both direct and indirect food contact, this breakthrough technology delivers food-safe, durable, and recyclable printing—without the need for an additional functional barrier.

Food-safe and durable printing on paper, without varnish?

Discover our unique TITON dry toner

Superior deinking

Xeikon’s dry toners achieve an impressive 90/100 on the International Association of the Deinking Industry’s efficiency scale—making recycling easier than ever.

Water-smart printing

Our dry toner technology minimizes water use, with only a closed-circuit cooling system for the printheads—no excess waste, no unnecessary consumption.

Ethically sourced, harm-free

We carefully select raw materials to ensure our toners are ethically sourced and free from harmful substances, so you can print with confidence.

Unmatched substrate flexibility

Print on any substrate you have in stock—no need to rely on specific paper mills or brands. Dry toner technology gives you total freedom.

Powered by green energy

Sustainability starts at the source. The Xeikon toner and press assembly plant operates on 100% green energy, reducing your carbon footprint.

Sustainable. Food-safe. Paper-based.

With the TX500 and TITON toner, you can produce food-safe, flexible packaging without the need for varnish or laminates—better for your business, and the planet.

For sustainable printing of flexible, paper-based food packaging

With the Xeikon TX500 and TITON technology, reducing plastic in your packaging has never been easier. Stay ahead of EU regulations and meet consumer demand for sustainable solutions—without compromising on safety or quality. This unique technology delivers food-safe, recyclable, and eco-friendly printing on paper-based flexible packaging, helping you future-proof your brand.

Additionally, Xeikon’s TITON toner is PFAS-free, unlike many competitor technologies that still rely on these chemicals for barrier performance. With Xeikon, you ensure compliance with upcoming PFAS regulations while maintaining the highest standards in food safety and sustainability.

Committed to long-term sustainability

At Xeikon, sustainability isn’t just a goal—it’s part of who we are. As a proud partner in the Flint Group 2030 Strategy, we align with the United Nations Sustainable Development Goals to drive meaningful change. Our commitment runs deep—back in 2009, we cut our carbon footprint by 50% simply by switching to green energy.

In addition, Xeikon’s TX500 presses consume significantly less water and energy than traditional flexo and solvent-based printing systems, ensuring a lower environmental impact at every stage of production.

Where to start with sustainable, paper-based, flexible packaging?

Looking to transition to paper-based, flexible food packaging with cutting-edge digital technology?

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Paperbased Flexible Packaging

Printing sustainable, flexible food packaging: how do you make it happen?

High-tech alternatives for plastic packaging

The rise of paper-based, flexible packaging

Which substrate is best for you?