BOBST Expands Water-Based Flexo Printing Capabilities

Founded in 2017, Roclayer operates out of Vila Velha de Ródão, Portugal, serves customers across the Iberian Peninsula, and has built an enviable reputation for paper-based flexible packaging innovation. Roclayer runs a lean, technologically advanced operation with 70 employees focusing on high-value, customized packaging for demanding sectors, including food and pharmaceuticals.

Tackling the drying challenge
Roclayer had previously invested in the BOBST EXPERT CI flexo press, equipped for both solvent- and water-based inks. To better meet the needs of its customers, the company upgraded this press with BOBST Full Surface Matrix Dryer (FSM Dryer), a next-generation drying system designed to enhance performance in water-based flexo printing.

Unlike conventional slot nozzle drying systems, the Full Surface Matrix Dryer delivers uniform hot air across the entire print width, with three times the coverage per ink dot. It improves register accuracy, reduces residual solvent concentrations by over 20%, and supports print speeds above 400 m/min on water-based print jobs.

The retrofit has had a noticeable impact on production. It was essential for improving the application of water-based and aqueous suspensions, helping Roclayer meet growing demand for more sustainable printing solutions. Since the upgrade, the company has seen greater production efficiency, particularly on niche products and high added-value jobs. This improvement has strengthened Roclayer’s ability to stand out in a competitive market by offering differentiated, high-quality results.

Roclayer’s relationship with BOBST began with the company’s founding project, which included a 2.5-meter extruder and the BOBST EXPERT CI flexo press. From that point forward, the two companies have worked closely across multiple technology and service touchpoints. For Roclayer, the value of the partnership goes far beyond the hardware.

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