Investing Big To Upgrade Digital Manufacturing! Senlin Packaging Launches Its Customized Roll-to-roll Digital Inkjet Color Printing Packaging Production Line

Recently, Forest Packaging Group Co., Ltd., the president unit of the Taizhou Packaging Association, successfully launched its brand-new customized roll-fed digital inkjet color printing packaging production line. The project cost over ten million yuan and has established a benchmark in the industry for a smart production base that can handle small batches, multiple varieties, and fast delivery of flexible color-printed packaging.

This production line is equipped with the largest-width roll-to-roll digital inkjet press in China, alongside four independently developed core invention patents. It fully connects the entire digital short-run packaging production chain, marking the company's dual leadership in technology and capacity in the digital flexible printing field.

Major investment in large-format digital production
Integrated setup of full high-end equipment

The newly installed production line centers around the HanHua 2200 digital inkjet press as the main core equipment. The machine features 64 high-end industrial printheads from Japan's Kyocera, delivering stable 600DPI high-definition print quality with rich image layers and delicate, full color reproduction. Continuous long-term production ensures controllable color variation, and its high-end color print quality rivals traditional premium printing.

As the domestic leader in roll-to-roll digital inkjet width, the large-format machine greatly improves single-roll production efficiency, breaking through the capacity limits of narrow-width digital devices while accommodating both batch short runs and customized orders. The entire line achieves integrated automated operations from roll feeding - digital inkjet printing - online high-precision cutting - to finished product post-processing, significantly reducing manual handling, shortening process turnaround time, and providing 24/7 continuous industrial production capability far superior to segmented traditional lines.

Supported by four independently developed invention patents
Building a proprietary digital printing technology system

Drawing on years of digital packaging R&D, Senlin Packaging has also developed four proprietary roll-to-roll inkjet printing core invention patents. With deep hardware and software collaboration, it forms an industry-unique flexible printing technology system. The four patents are:

1. A production process for large-format roll-to-roll inkjet printing: Optimizes preheating, inkjet, and drying processes for 2200-mm ultra-wide rolls, solving common industry issues like paper deformation and incomplete ink drying, improving wide-format print stability and product pass rate.

2. Application of roll-to-roll inkjet printing process for imposition: Enables intelligent layout consolidation for multiple small orders, automatically sorting by width and color data, reducing cleaning and ink cartridge wastage during job changes, and enhancing overall equipment utilization, thereby cutting small-run production costs from the process side.

3. A control method for roll-to-roll inkjet printing: A full-process digital closed-loop control system that adjusts ink output, material tension, and paper feed speed in real time to dynamically correct print deviations, ensuring high consistency in color and size quality across different batches and orders.

4. A printing method for small-batch personalized orders: Establishes a lightweight order processing workflow, eliminates traditional pre-press steps, assigns jobs with one click after file submission, perfectly fitting high-frequency iterations and multi-specification customized orders, enabling a true "print starting from one sheet" flexible production model.

These four patents cover production process, imposition optimization, equipment control, and order processing, fully integrating with the new large-width production line and directly translating R&D achievements into market competitive advantages.

Disrupting Traditional Printing Models

Solving the Pain Points of Small Batch Orders

Traditional gravure and flexo printing have drawbacks such as long plate-making cycles, high setup costs, high minimum order quantities, and significant waste when changing orders, making it hard to meet the current market demands of quick trial sales, fragmented short orders, and fast iteration for e-commerce, food, daily chemicals, and cultural creative brands. Forest Packaging's brand-new digital production line completely eliminates the complicated plate-making process, allowing clients to start printing as soon as their designs are finalized, greatly shortening production cycles from the start and reducing the overall cost of small batch orders.

The production line is highly flexible, capable of handling various customized color printing packaging tasks, accommodating multiple specifications, small batches, high-frequency orders, and urgent deliveries. It truly enables printing from a single sheet, ready for immediate pickup, with consistent batch quality. Compared to traditional printing, the delivery time for new product samples is reduced by over 70%, and hundreds or thousands of small orders don't incur high plate-making costs, providing cost-effective custom packaging solutions for small and startup brands. At the same time, it significantly reduces plate-making material and ink waste, aligning with the trend towards green and low-carbon packaging.

Leading Industry Transformation

Creating a Digital Packaging Model in Taizhou

As the president unit of the Taizhou Packaging Association and one of China's top 100 printing and packaging enterprises, Forest Packaging has been deeply involved in the entire packaging industry chain for over 20 years. The company has built an integrated industrial layout including recycled paper, cogeneration, papermaking, and green packaging, continuously increasing investment in digital printing and smart manufacturing R&D. Holding nearly a hundred related packaging patents, it is a core leader in the digital upgrade of the regional packaging industry. The launch of the 15-million-investment large-format digital inkjet production line is a key step in implementing the company's "innovation-driven, smart manufacturing" strategy. It fills the gap in high-end short-run color printing capacity and creates a replicable demonstration model for the digital transformation of the packaging industry in Taizhou and even Zhejiang.

Looking ahead, Forest Packaging will leverage ultra-large digital equipment, self-developed patented technology, and full industry chain support to continually expand the personalized color printing packaging market. Using digital flexible production capabilities, it aims to empower brand clients across the supply chain and promote the regional packaging industry's upgrade from traditional mass production to efficient, flexible, and green digital intelligent manufacturing.

Industry insiders point out that the current trend in the packaging market is fragmented and customized orders in the long term. Large-format roll-to-roll digital inkjet printing is a key track for industry upgrading. Forest Packaging's simultaneous hardware and software upgrades, combined with four exclusive invention patents, create differentiated competitive advantages that will further solidify its leading position in China's digital color printing packaging sector and provide a reference model for the digital transformation of packaging and printing enterprises nationwide.