Roclayer enhances water-based flexo printing with Full Surface Matrix Dryer retrofit on BOBST EXPERT CI flexo press

An agile, sustainability-driven packaging specialist 
Founded in 2017, Roclayer operates out of Vila Velha de Ródão, Portugal, serves customers across the Iberian Peninsula, and has built an enviable reputation for paper-based flexible packaging innovation. Roclayer runs a lean, technologically advanced operation with 70 employees focusing on high-value, customized packaging for demanding sectors, including food and pharmaceuticals. 

“Our industry, and the wider packaging market, are both evolving rapidly,” said Luis Gonçalves, General Director at Roclayer. “Customers want more sustainable solutions, shorter lead times, and dependable performance, even on the most challenging substrates. That means to stay competitive, we have to stay at the forefront of technology.” 

Tackling the drying challenge 
Roclayer had previously invested in the BOBST EXPERT CI flexo press, equipped for both solvent- and water-based inks. To better meet the needs of its customers, the company upgraded this press with BOBST Full Surface Matrix Dryer (FSM Dryer), a next-generation drying system designed to enhance performance in water-based flexo printing. 

“The drying system around the CI flexo press was completely replaced with the latest version,” said Gonçalves. “It was a major move, but it brought significant improvements in drying efficiency and production performance, especially with aqueous inks.” 

Unlike conventional slot nozzle drying systems, the Full Surface Matrix Dryer delivers uniform hot air across the entire print width, with three times the coverage per ink dot. It improves register accuracy, reduces residual solvent concentrations by over 20%, and supports print speeds above 400 m/min on water-based print jobs. 

The retrofit has had a noticeable impact on production. It was essential for improving the application of water-based and aqueous suspensions, helping Roclayer meet growing demand for more sustainable printing solutions. Since the upgrade, the company has seen greater production efficiency, particularly on niche products and high added-value jobs. This improvement has strengthened Roclayer’s ability to stand out in a competitive market by offering differentiated, high-quality results.  

“Our customers are seeing the benefits too,” Gonçalves added. “For jobs with high ink coverage, we’re now much more efficient and consistent. That translates to faster deliveries and fewer reprints. 

“We’ve always seen technology as a foundation for growth,” said Simao Rocha, Chairman at Roclayer. “But more than that, it’s about who you choose to build with. Our partnership with BOBST has been there since day one, and it continues to play a critical role in how we evolve as a business.” 

Roclayer’s relationship with BOBST began with the company’s founding project, which included a 2.5-meter extruder and the BOBST EXPERT CI flexo press. From that point forward, the two companies have worked closely across multiple technology and service touchpoints. For Roclayer, the value of the partnership goes far beyond the hardware. 

“Thanks to the support, technical assistance, and training we’ve received over the years, we continue to grow day by day,” said Rocha. “BOBST machines are reliable and profitable, but just as important is the expertise behind them. We know we can count on BOBST for the support we need to meet our goals.” 

That ongoing trust is built into BOBST own philosophy of collaboration. 
“BOBST never aims to be ‘just’ a supplier,” said Alessandro De Nobili, Performance Solutions Manager at BOBST. “We approach every partnership with the understanding that each business is unique. Whether it’s a new press or a targeted retrofit like Roclayer’s, our role is to support our customers with tailored solutions that help them stay competitive, productive, and forward-looking. 

“We’ve built a fantastic relationship with the Roclayer team,” Alessandro De Nobili added. “From its first investment in a BOBST extruder and CI flexo press, to supporting their broader setup which now includes slitter-rewinders, a shearing machine, and an intelligent robotic warehouse - it’s been a partnership in the truest sense. What makes working with Roclayer so rewarding is its clear vision, technical capability, and willingness to innovate. We’re proud to be part of that journey.” 

For Roclayer, the retrofit wasn’t just about improving a single process - it was about reinforcing the foundation of its business and continuing to lead with confidence in a fast-changing market. 

BOBST