Exclusive: Actega targets 100% plastic waste reduction with Ecoleaf at Interpack

Harald Jasper, managing director of Actega Metal Print, says the industry is pivoting toward a “waste-free” metallisation model that eliminates carrier foils and slashes energy consumption by 80% compared to traditional processes.

Jasper identifies the move away from traditional cold and hot foiling as a “complete new way of thinking” for converters. Unlike conventional methods that require laminating a metallised reel against a substrate only to delaminate it and discard nearly 90% of the metallic material as waste, Ecoleaf utilises a continuous, pigment-on-demand process.

“It is a huge change because today, metallisation involves buying a metallised reel, and most of that metallic is waste,” Jasper says. “Ecoleaf only brings the pigments where we need them. We have no waste and we do not transport reels to the customer,” he adds.

Zero waste and 100% plastic reduction

The technical advantage of the system lies in its ability to eliminate carrier foils entirely. For a standard label printer, Jasper says this equates to a 100% reduction in plastic waste. He notes that the environmental impact goes beyond the press floor, removing the need for polymer granules, film extrusion, and the logistics of transporting and disposing of heavy reels.

This efficiency translates directly into a reduced carbon footprint. Jasper says that on a typical label where 10% to 15% of the surface area is metallised, switching to Ecoleaf reduces the carbon footprint by over 80%. This reduction has piqued the interest of major global brands in the cosmetics, haircare, household, and spirits sectors, specifically in high-end whisky packaging where gloss and sustainability are equally prioritised.

Integration and digital agility

A key hurdle for any new technology is integration into existing production lines. Jasper explains that the Ecoleaf unit is designed to be installed on the rail of any existing narrow-web press in the market. “We have been thinking about two markets: Existing presses and new presses,” he says. For new investments, the unit can be integrated at the floor level within the machine supplier's special module.

The technology consists of two parts: Printing a binder (trigger image), curing it, and then passing it through the Ecoleaf unit to pick up pigments. While the trigger image can be printed via flexo or rotary screen, Actega’s partnership with Fujifilm Integrated Inkjet Systems has introduced an inkjet trigger image to meet the just-in-time demands of the modern supply chain.

“The market demand for just-in-time delivery is increasing tremendously. A major brand might order at 3 pm and expect delivery at 7 am the next morning,” Jasper says. By utilising Fujifilm Samba heads, these digital lines now run at speeds between 50-m/min and 80-m/min, providing the agility needed for high-resolution, short-notice production.

The Indian perspective: Balancing gloss and cost

In price-sensitive markets like India, the conversation often begins with the bottom line. However, Jasper says that sustainability is now a co-driver for Indian brand owners. He notes that the transition is no longer just about the environment but about achieving beautiful gloss with some saving.

As the industry looks toward 2030 Net Zero targets, Jasper believes the adoption of such continuous processes, which also offer better ink adhesion on top of silver compared to traditional foils, will become the industry standard. He concludes that the combination of productivity gains and the total elimination of waste makes the technology an easily explainable return on investment for converters worldwide.