Pałucka Drukarnia Opakowań (PDO) is realizing substantial cost savings, efficiency gains, and environmental improvements following its adoption of expanded color gamut (ECG) printing, made possible by FLEXCEL NX plates and PureFlexo Printing technology from Miraclon. CEO Karolina Olejniczak credits the combination as “the key enabler” of PDO’s successful transition, noting that it has increased production capacity, minimized waste, and enhanced sustainability outcomes for customers without compromising visual impact.

A recent collaboration with Segafredo Zanetti Poland demonstrates the full potential of ECG. PDO reengineered the Intermezzo coffee bean packaging from a 7+white design to 4+white, reducing ink consumption by up to 40 percent while doubling press speed from 200 m/min to 400 m/min. The shift significantly decreased energy use and ink waste, all while maintaining the bold shelf presence expected of the brand.

PDO’s embrace of technically advanced packaging began with a strategic transformation in 2011, when the company committed to pioneering innovative, high-performance packaging solutions with improved recyclability. Today, PDO serves major brands across Germany, Italy, the Netherlands, Austria, and Scandinavia from its Janowiec Wielkopolski facility, with food packaging accounting for 80% of its output. The company has invested heavily in new flexo technology, including a 10-color CI press and a dedicated R&D centre established in 2018 to advance sustainable materials and barrier solutions.

Miraclon’s FLEXCEL NX plates have been central to this journey. PDO uses them exclusively, citing superior ink transfer, plate durability, and high-speed stability. PureFlexo Printing, part of the FLEXCEL NX Print Suite, delivers advanced surface patterning that reduces ink spread and dot gain, enabling the precision required for successful ECG production.

PDO commercial director Malgorzata Rein underscores the value of collaboration: “When we saw how PureFlexo Printing supported ECG printing, it aligned perfectly with our sustainability objectives. Segafredo recognized the efficiency and environmental gains immediately.” The success of the Intermezzo project has led Segafredo Zanetti Poland to plan a complete transition to ECG and recommend the approach across the wider Massimo Zanetti Beverage Group.

For PDO, the results affirm a long-term strategy built on knowledge, innovation, and sustainable production. As Karolina Olejniczak explains, “When customers see the quality we can achieve with fewer colors, concerns disappear. ECG is delivering exactly what brands need, visual impact with lower environmental cost.”