Orora launches Helio digital printing to revolutionise beverage can design

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Orora Beverage has launched Helio by Orora, a new direct-to-shape digital printing solution set to transform beverage can decoration and accelerate time-to-market for new products and promotional campaigns.

Developed in partnership with global technology provider Velox-digital, the high-speed digital decoration system marks a first for the primary packaging market in Oceania. 

The inaugural digital printer will be installed at Orora’s Dandenong can production facility in Victoria, Orora said in a news release. 

Chris Smith, general manager of Orora Beverage Cans, said the new technology would significantly enhance the company’s ability to support customers in a competitive market. 

“We have been assessing the development of direct-to-shape digital decoration technology for cans for some time,” Smith said. “We’re thrilled about our new technology choice and the introduction of Helio enabled by high-speed digital decoration capability.”

Helio offers an expanded design capability that includes full-colour gradients, textures, and high-resolution graphics, allowing brands to customise can designs with greater detail and flexibility than previously possible using traditional offset printing. 

Orora said the new digital printing process eliminates the need for printing plates, enabling faster turnaround times and smaller production runs.

“Once commissioned, what this means for our customers is that wait time will be significantly reduced in delivering a specific can size or label design for activities such as promotions, new products and limited-edition retail events,” Smith said. 

“With no label set-up required and near-immediate supply, shorter, faster minimum runs can be accommodated, providing greater flexibility in product and campaign planning.”

The company said Helio will complement recent capital investments in can manufacturing, including the $80 million multi-size can line at Dandenong, completed in June 2023. 

That project increased production capacity by approximately 10 per cent and added the ability to produce a wider range of can formats. 

Additional investments include a $30 million expansion of can ends capacity at Ballarat completed in March 2023, and an $85 million can line under development in Revesby, New South Wales, scheduled to come online in early 2025.

Orora said the Helio technology enhances its service offering at a time of strong growth in the aluminium cans market, driven by increasing demand in categories such as craft beer, soft drinks, ready-to-drink beverages, and seltzers.

“We know that can graphic design and decoration is a critical tool for engaging consumers,” Smith said. “With strong in-house can decoration capability, the Helio solution adds even greater value to Orora’s offering for its customers.”

The company also highlighted the sustainability advantages of aluminium cans, noting that they are made from recycled content and are infinitely recyclable.