New series featuring the voices of ERA members
Member Spotlight: A. Hatzopoulos S.A.
Welcome to the first edition of our ‘Member Spotlight’ series, designed to shine a light on the diverse perspectives and experiences of our member organisations. Spanning the globe, our members offer unique insights into industry trends, challenges and innovations. By featuring their voices, we aim to foster a deeper understanding of the gravure printing landscape and wider print industry.
We put our most pressing questions to A. Hatzopoulos S.A. team, one of the fastest growing packaging converters in the European market, covering everything from technological innovations to sustainability challenges.
Industry trends and challenges
ERA: What do you see as the biggest challenge facing the Gravure print segment today?
Ioannis Giannakopoulos (Plant Manager): The gravure print segment is facing several significant challenges, including a lack of experience among younger workers, which contributes to a skills gap as older employees retire. There is also a personnel shortage, as many potential employees are disinterested in factory work, making it challenging to attract and retain skilled labour.
“The rise of cheaper printing technologies,
such as flexographic and digital printing,
poses a serious threat.”
The increasing demand for shorter print runs further complicates matters, as gravure printing is typically more cost-effective for longer runs. Finally, the rise of cheaper printing technologies, such as flexographic and digital printing, poses a serious threat, as these alternatives often offer lower costs and faster turnaround times, making them more appealing to clients.
Addressing these interconnected challenges is crucial for the gravure print segment to remain competitive in an evolving market.
Technology and Innovation
Which new technologies have had the most significant impact on your gravure printing operations in the past year?
Ioannis Giannakopoulos (Plant Manager): Several new technologies have significantly impacted our gravure printing operations in the past year. Our company has prioritized investing in employee training to ensure our team is skilled in the latest techniques and best practices. We actively monitor developments in the industry and implement necessary upgrades to our machines to stay competitive. Additionally, we’re exploring innovative methods to reduce costs and enhance productivity, such as “extended color gamut” printing.
Are you currently using or planning to invest in process or material change to make your products more sustainable?
Leutheris Tourasanidis (R&D Manager): Packaging is extremely important to protect food and combat food waste, and Hatzopoulos is developing materials that are both lightweight and can be recycled in a circular way. The target is to change our portfolio, to high-performance, efficient-proof, and compatible with packages add-ons (like degassing valves – zippers – stickers) recyclable materials. Incorporating the industry guidelines for flexible packaging design for recycling, we develop monomaterial PP or PE and mixed Polyolefin laminates, focusing on recycle-ready solutions for all recycling streams, where available, and keeping protection and functionality at current level, or even at an advanced level, always in accordance with the market demands.
Business Development and Growth
What are your biggest challenges in attracting and retaining skilled talent in the print industry?
Eleutheria Papardeli (HR Manager): The printing industry faces challenges in attracting and retaining top talent due to skill shortages, particularly in specialized technical areas. The rapid pace of technological advancements is also a challenge, as it requires continuous adaptation, upskilling and investment in employee training. Additionally, competition with other industries for skilled workers can be intense, especially in tight labor markets.
Sustainability and Environmental Impact
What steps has your company taken to reduce its environmental impact?
Giorgos Gikas (QA Manager): We have implemented several initiatives to minimize our environmental impact. First, we’ve moved from using oil to natural gas for our boilers. We’ve also installed photovoltaic panels that now generate more than 10% of our electricity needs. We are also working towards achieving zero waste to landfill by responsibly disposing of all industrial waste. Additionally, we have upgraded our vehicle fleet to hybrid models to cut down on emissions, and we also collect rainwater, storing it in tanks for use in irrigation and firefighting systems. To ensure continuous improvement, we conduct regular energy audits, which help us identify areas for enhancement. This includes implementing energy-saving measures like replacing outdated equipment with more efficient options and recovering heat to meet our building’s thermal needs.
What impacts are you expecting to see from EU or local government legislation (e.g., PPWR)?
Giorgos Gikas (QA Manager): There are many! Compliance is a big one – businesses will face increased costs associated with ensuring compliance with stricter rules on packaging while recycled content mandates could force companies to source more expensive, recycled materials, driving up production costs. But I think we will also see a more circular economy emerge, as companies attempt to shift from single-use plastic packaging to materials that can be reused or easily recycled, and this will lead to a reduced environmental impact overall.
As these changes unfold, retailers and manufacturers will need to adapt, potentially leading to a rethinking of supply chains and a stronger focus on environmentally friendly packaging. This could result in innovative product designs using compostable materials or less packaging overall. We also expect increased transparency and reporting, as companies will be expected to provide detailed data on their packaging and its recyclability – they may have to implement better tracking systems for the materials they use as well as their environmental impact.
“While regulations might pose initial challenges,
they also open up opportunities for companies
that embrace innovation early, giving them a competitive edge
in sustainable practices.”
As the PPWR is expected to strengthen Extended Producer Responsibility schemes, producers will have to financially manage the collection, sorting, recycling, and disposal of their packaging waste. They will also need to cover the costs of litter clean-up, adding a financial burden on businesses that use non-recyclable or hard-to-recycle materials. Compliance with the PPWR could also cause supply chain disruptions, especially if certain materials become more restricted, so businesses may need to find new suppliers of compliant packaging materials or modify their existing processes.
While these regulations might pose initial challenges, they also open up opportunities for companies that embrace innovation early, giving them a competitive edge in sustainable practices. Overall, while there may be short-term cost increases translating to higher consumer prices, this might be balanced by the long-term environmental and social benefits of sustainable packaging.
Networking and Community
How do you stay connected and engaged with other professionals in the print industry?
Ioannis Giannakopoulos (Plant Manager): At A. Hatzopoulos, staying connected and engaged with other professionals in the print industry is essential for our ongoing innovation and growth. We prioritize active participation in industry events and trade shows, where key players in print and packaging technology gather to exchange ideas, present new solutions, and explore collaborations. These events offer us a platform to connect with manufacturers, suppliers, and innovators across the value chain, ensuring we stay at the cutting edge of technological advancements and market trends.
We also maintain strong relationships through our involvement in various associations, including ERA, where we collaborate on initiatives related to sustainability and circular economy practices in flexible packaging. These forums allow us to engage in important discussions about the future of packaging materials, environmental regulations, and consumer demands, while networking with professionals who share our commitment to innovation.
Additionally, we foster connections through our digital presence and by maintaining open channels with our partners, ensuring that we are not only aware of, but actively contributing, to the ongoing evolution of the industry.
Future Outlook
What changes or innovations would you like to see in the print industry in the near future?
Leutheris Tourasanidis (R&D Manager): Traditional printers-friendly materials, like BOPET, BOPP and OPA, will change in the near future to new and more challenging, coated and non-coated, PE and/or PP substrates. The print industry should invest in technologies (tension control, registration aids, drying innovations, inks and varnished compatible with new era coatings and functional materials, etc.) which enable the printers to maintain the highest level of print quality and to finally produce recyclable structures, achieving both goals: keeping the market satisfied and the environment safe.
Thank you, A Hatzopoulos, for taking the time to answer our questions! If you’ve enjoyed reading this and would like to get involved in our ‘Member Spotlight’ series, get in touch with Stefani Dhami at stefanidhami@era-eu.org
