Flexographic Technical Association (FTA) has named XSYS and GEW as winners of its 2025 Sustainability Excellence Awards. GEW was cited for innovations in sustainability, while XSYS was feted for enhanced products and processes.

Product lines heralded were: nyloflex eco series plates by XSYS and the AeroLED2 UV Curing System by GEW.

Bio-Based Plate

nyloflex eco series plates by XSYS, were said to demonstrate “a groundbreaking innovation in flexographic printing.” With bio-based raw materials representing 29% of content, eco series plates match or exceed quality and performance of traditional media, at the same time they reduce reliance on fossil-based components.

XSYS eco series plates come in two varieties—ACT a hard photopolymer plate for the perfect combination of halftones and solids that is exclusive to paper and board applications; and FAC, a medium specific to high performance corrugated post print, that copes with all requirements for rough-to-sensitive board stock and soft paper substrates.​

XSYS reports, “This product series delivers measurable improvements in processing speed and energy efficiency, directly addressing customers’ requirements for a reduced environmental footprint and holding true to the eco series slogan, ‘Lifting proven quality to a sustainable future.’”

The company also observes, “Traditional printing plates rely heavily on petroleum-based raw materials, which are carbon-intensive and a finite resource.”

It notes that industry data indicates that the global consumption of flexographic printing plates is on the order of 7–8 million square meters annually, with all projections pointing to steady growth in demand and continuing expansion of package printing through 2030 .

XSYS’ assurances to converters with interest in bolstering their reputation for environmental responsibility, came in this message, “Fossil-based raw materials constitute a significant share of plate weight across the industry. Replacing even a portion with bio-based alternatives will reduce reliance on finite and high-impact resources and lessen upstream emissions.”

UV LED Curing

GEW’s AeroLED2, an air-cooled UV LED curing system for full cure, printing, coating and converting applications, features the power to meet productivity demands while delivering energy savings of better than 55% over traditional mercury arc lamps. 

The manufacturer maintains, “AeroLED’s interchangeable lamphead cassettes enable Arc and LED to be run side-by-side on a single press.” According to GEW, “It is the only air-cooled ArcLED – hybrid UV/LED–system available on the market. AeroLED2 incorporates suction cooling for significant process advantages.

AeroLED’s use of negative cooling for quieter, more reliable operation ensures that no air is exhausted into the machine, eliminating the risk of heat and contamination on and around the press.”

“Air cooling is more reliable than water-cooling and is preferred by the industry. It is less expensive to install and run as it requires less energy.” GEW engineers report. “For companies adopting AeroLED2 curing technology, improvements are clear: reduced carbon footprint; elimination of ozone, and the need for mercury; significant energy and cost savings; improved curing process consistency and reliability; substantial saving in consumables.”

Developers note, “Heat generated during the LED curing process is significantly lower than that of UV Arc systems, and this in turn can greatly reduce the need for HVAC and other energy-intensive air management equipment. Waste hot air can be ducted into or out of premises. This further energy saving is not possible with forced air systems.”

One definitive benefit they stress again and again, “UV LED curing does not require any mercury as Arc lamps do, nor does an LED system produce any ozone.”

In AeroLED2: “Power, UV dose and irradiance have been increased to ensure effective curing with all leading LED-curable inks on the market,” GEW contend. “Maximum width available has been increased to 70 cm, ensuring compatibility with the vast majority of label and web presses in operation today.”