Agfa, Hybrid Software partner to enable fully digital folding carton production with variable data printing

BELGIUM – Agfa and Hybrid Software have formed a partnership to help folding carton converters leverage variable data printing and shift to fully digital production, combining Hybrid’s tools for packaging design, pre-press, and digital front-end workflow with Agfa’s SpeedSet Orca single-pass press and Asanti software.

The joint offering allows converters to produce folding cartons with different graphics, text, languages, and artwork from one unit to another, supporting a flexible and scalable digital production process while meeting quality and consistency standards needed in packaging.

The SpeedSet Orca press is built for digital folding carton work in higher-volume settings, with features such as quick job changeovers and lower waste.

The Shift from Analogue to Digital

Agfa software digital printing systems head Michael Dupré commented that this collaboration reflects a shared commitment to helping folding carton producers navigate the shift from analogue to digital production, especially as demand for versioning and customisation continues to grow. 

The SpeedSet Orca press combines digital primer, water-based inks, and inline varnish, handling paper and micro-flute substrates to allow different packaging applications to be produced on the same digital platform. 

The press is aimed at jobs where conventional production approaches become less effective, specifically short-to-medium runs with frequent design changes.

SmartDFE for Inline Variable Data

The integration includes SmartDFE from Helix, Hybrid Software’s OEM business, for inline variable data printing. 

The companies said SmartDFE uses patented AI software to adjust system configuration in real time to improve production speed and efficiency, including for jobs with many versions.

Variable data printing allows each carton in a run to carry different information, regional language requirements, seasonal promotions, or personalised QR codes, without slowing the press or requiring separate plate changes.

Colour Management Across Versions

The package also includes colour management software from Hybrid’s ColorLogic, which the companies said is intended to keep brand colours consistent across versions and substrates. 

For folding carton converters, maintaining colour fidelity when switching between different paperboards or running short, versioned jobs has traditionally required extensive manual adjustment. 

Automated colour management reduces setup time and waste.

Hybrid Software Helix EMEA OEM sales director Lawrence Geere added that by combining the expertise of the Agfa and Hybrid Software engineering teams, the collaboration aims to help converters unlock the full potential of digital production, providing a clear, practical path to compete in a rapidly evolving market.

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