In a fast-changing and unpredictable packaging environment, a willingness to adapt and invest can help companies stay ahead. That’s certainly true of RotoFlexoPress (RFP), a converter based in the Lebanese mountain town of Dhour Choueir, specialising in manufacturing, printing, and converting of flexible packaging. Established in 1970, the company has grown and evolved over the years, expanding its reach to Europe, Africa, and the GCC countries, and today is at the very forefront of sustainable and innovative packaging manufacturing.
The company’s most recent investment is a BOBST NOVALAM S 550. Facing growing demand for barrier solutions, food grade packaging, and recognising that precision, efficiency, and reliability were non-negotiables, the team at RFP were convinced by the machine’s superior lamination quality, advanced web tension control, and high production speed.
Ideal for RFP’s diverse product range of bags, pouches, sleeves, and roll stock, the versatile BOBST NOVALAM S 550 is designed to handle a variety of substrates including thin alu-foil, metallised film, and thin stretchable materials. Notably, the machine boasts a super-quick plug and play installation process, allowing it to be fully operational within five days of arrival at the customer’s site.
“Since installing the NOVALAM S 550, we’ve increased lamination output by 30%, while downtime has dropped by 35%, saving 10 man-hours per week,” says George Habib, Managing Partner at RFP. “The improved efficiency has helped us to boost sales by 12% and attract three new international clients.”
Focused on Sustainable Future
Sustainability is a major focus for RFP – in part out of necessity. Lebanon’s unstable electricity grid and dependence on diesel generators significantly increases operational costs and disrupts production continuity. To mitigate this, RotoFlexoPress is actively investing in solar energy solutions and battery storage systems, ensuring greater energy independence, cost efficiency, and reduced environmental impact.
The NOVALAM S 550 contributes to the company’s push for greater sustainability too. “The NOVALAM’s solventless technology ensures reduced emissions and lower energy consumption, supporting our sustainability goals and long-term cost savings,” says RFP Managing Partner Joseph Habib. “We have seen waste reduce by 20% and energy use reduce by 15%, helping us to reduce both costs and environmental impact.”
Progressive Partnership
After a rapid plug and play installation at RFP’s site, BOBST’s technical team provided hands-on training to ensure a smooth start, enabling RFP’s operators to reach full production capacity quickly, minimising downtime and accelerating ROI from day one.
The NOVALAM S 550 is not the first BOBST machine for RFP. The company began its partnership with BOBST back in 2012 with the acquisition of an FP-15S flexographic press, driven by a strategic move to enhance print quality, increase production efficiency, and work with a wider range of substrates. It was a pivotal moment for the company, allowing RFP to meet growing regional and international demand for high quality flexible packaging.
“Partnering with BOBST also aligned us with global standards and laid the groundwork for a long-term collaboration in technical support, operator training, and continuous innovation,” says Bassam Habib, Managing Partner at RFP. “BOBST machines stand out for their unmatched reliability, precision engineering, and advanced automation, which translate into higher productivity and reduced waste. Compared to other manufacturers, BOBST offers superior build quality, intuitive interfaces, and faster job changeovers, all of which improve operational efficiency.”
Khaled Joundi, BOBST Zone Business Director Middle East, Egypt & Pakistan, shares his enthusiasm about the partnership with RotoFlexoPress: “I’m genuinely proud of the work we’ve done to bring this deal to life. Partnering with this important Lebanese company feels like more than just business, it’s a meaningful step forward for both sides. It’s always rewarding to see collaboration turn into something real and impactful.”
Laying Foundations for Tomorrow
RFP continues to grow and evolve to meet the needs of tomorrow. To further strengthen the company’s commitment to sustainability, RFP is installing 160 lithium batteries and 270 additional solar panels, bringing the total to 1,310 panels. This major investment will enhance RFP’s energy independence, while significantly reducing the company’s carbon footprint, reinforcing its position as a forward thinking, eco conscious manufacturer.
“This move allows us to optimise energy use, reduce costs, and ensure more resilient operations benefiting both our business and our clients who value responsible, future ready partners,” says Bassam. “At the same time, we are moving our business toward greater specialisation in sustainable and customised packaging solutions, with a strong focus on serving emerging brands and startups. As demand grows for ecofriendly materials, digital integration, and flexible production, we aim to expand our capabilities in high value, tailored packaging, supported by investments in advanced machinery and automation.”
