Paxxus powers precision healthcare packaging with dual Master M6 investments

Packaging Solutions

Bobst's Master M6 in line flexo presses have enabled Paxxus Ireland to significantly enhance and streamline its healthcare packaging production. With two now installed at its County Cork facility, a seven colour model in 2023 and a four colour model in 2024, the company has positioned itself for both maximum flexibility and long term operational resilience.

Paxxus is a leading global supplier of engineered flexible materials and packaging solutions for the global healthcare market, recognised for its expertise in high barrier films, foils, composites and peelable solutions. It proudly supports the entire healthcare industry, serving pharmaceutical, medical device, diagnostic, and related sectors.

Before investing in the Bobst presses, Paxxus Ireland was running two aging flexo machines dating back to 1997 and 2004, respectively. ‘We got everything we could out of them,’ said Ciaran Foley, managing director at Paxxus Ireland. ‘But we knew we needed to step up. We weren’t just replacing physical machines; we were upgrading the entire way we work.’

The decision to go with Bobst came after an extensive evaluation. The business sought flexo machines that could deliver premium print quality, fast changeovers, and reliable diagnostics, all critical factors for their low volume, quick turnaround, precision focused healthcare packaging work.

‘You need machines that just do what they say on the tin,’ said Ciaran. ‘The remote diagnostic capabilities, simplicity of access, and flexibility for add ons like die cut lidding and embossing – all that tipped the scale.’

A particularly important factor was fast changeover, in tandem with high running speed. As Ciaran explained, ‘With lower volume, quick changeover tasks, we don’t want a machine sitting idling for 10 to 15 minutes on set up before production even begins. That can be the difference between a profit and loss on some jobs.

‘With the Master M6, we are more productive. Our previous flexo machines typically ran between 50 to 90 metres per minute. With our new M6 machines, run speed is typically 80 to 140 metres per minute.’

Paxxus customised its seven colour Master M6 with modules for two side printing, pyramid embossing and die cutting, enabling a wider product offering for blister lids and calendar packs. The four colour M6, installed later, further enhanced the company’s capabilities in high volume, lower colour healthcare stock keeping units.

Ciaran estimates the company is now running jobs 35 to 40% faster, with changeovers significantly quicker compared to previous technology. Beyond speed, the shift has improved ergonomics for operators.

‘With our old presses, changing out heavy rollers was strenuous for our operators. They were heavy, and not particularly easy to handle. The new Bobst set up is not only lighter but designed for better accessibility,’ he explained. ‘That is critical in today’s market where skilled labour is hard to find and keep.’

As well as fitting effortlessly into the company’s cleanroom operations, Bobst's machines have also proven compatible with Paxxus' dual curing system requirement (LED and conventional UV), producing highly durable prints across aluminium, polyester and Tyvek substrates; essential for blister lids and other healthcare packaging applications.

Both M6 presses run everything from 12 micron polyester to complex laminates and even 360 microns PET.