#322 - Polytype: Precision, Packaging and the Journey to Digital. A conversation with Julien Bianchi, CEO

In this episode of the FuturePrint Podcast, Marcus Timson speaks with Julien Bianchi, CEO of Polytype, to explore the remarkable evolution of a company whose roots stretch back more than a century.

Originally emerging from Switzerland’s precision engineering tradition and the newspaper press industry, Polytype has transformed itself into a global leader in direct-to-shape packaging decoration. Julien explains how the pivotal founding of Polytype in 1962 marked the moment the company shifted its focus toward packaging, applying high-speed printing expertise to aluminium tubes, plastic packaging and other complex three-dimensional surfaces.

The conversation explores why Polytype deliberately chose the technically challenging path of direct-to-shape printing, and how that decision has shaped the company’s engineering philosophy and competitive advantage over decades.

Marcus and Julien also discuss how Polytype balances its long-standing expertise in dry-offset analogue printing with the growing opportunities of digital inkjet. Rather than viewing the technologies as competitors, Polytype sees them as complementary tools within a broader decoration toolbox.

The episode also delves into Polytype’s digital ecosystem strategy, including the development of its proprietary CALMAR inkjet platform, its open approach to ink supply, and the company’s partnerships with research institutions such as the iPrint Institute in Fribourg.

Finally, Julien shares insights into Polytype’s global footprint, the importance of service and long-term customer relationships, and how the company is preparing for the future through investments in automation, sustainability, and digital manufacturing.

A fascinating discussion on innovation, leadership, adaptability, engineering culture, and the evolving future of packaging decoration.

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Transcript

SPEAKER_00 0:01

Welcome to the Future Print Podcast, celebrating print technology and the people behind it.

SPEAKER_01 0:11

Welcome to the latest episode of the FuturePrint Podcast. I'm really happy to have with us today, for the first time, Mr. Julian Bianchi, who's the CEO of Polytype. Polytype are a new Future Print partner. So really excited to have Julian here to hear the, in essence, the Polytype story. So welcome to the podcast, Julian.

SPEAKER_02 0:34

Yes, uh, thank you, Marcus. Um, we are also really happy to be part of uh of the future print uh uh community, and I'm happy to be here today and share some uh some stories and topics with you.

SPEAKER_01 0:51

Brilliant. And and because this is the first time we've had you on the podcast, I guess I I I was fascinated to learn more about the story of Polytype and so on, the origin story. Obviously, Polytype today is known as a global packaging decoration business, a specialist in that area, but actually the roots go back a long way, don't they, more than a century. Could you perhaps start by taking us back to the very beginning and sort of explain a little about how the evolution of the business, because I believe it started in newspaper printing and evolved into something quite different. So, yeah, could you start by giving us a little bit of a backstory, perhaps?

SPEAKER_02 1:35

Yes, of course. Um poly type story is at the end deeply rooted uh in Switzerland's tradition of precision engineering. So uh our heritage uh goes back more than uh a century through VFAG. VFAG was a brand-based manufacturer that uh was globally known for its newspaper printing presses. Uh so we we had all this printing in the back that that started uh long years ago. And then uh Polytype emerged from that industrial know-how at the beginning of the 60s. Uh at that time the target was to diversify the activities. So the owners see that the newspaper is is is well, it's great, but they search really to find uh new markets. And um the company identified the opportunity to apply its printing expertise to a million aluminium tubes uh and later to the plastic tubes. Um they found it uh officially uh Polytype in 1962 uh in Fribourg because there were also some other partners. It was also a lot of uh promotion to bring industry in this city, and this was also one of the major opportunities to find the land to build the first um factory, and then to start and bring all the now-how from Bern to Fribourg. Um, but uh it's here really started to produce metal aluminium tubes and then uh start uh to go to tubes, plastic tubes, and then uh print on plastic cups.

SPEAKER_01 3:38

Yeah, and and and so 1962, by all accounts, is a real sort of pivotal year. But the leap from newspaper printing to packaging decoration is quite a significant one. What what what does that I guess tell us a bit about um the DNA within Polytype? Um it's a bit of an innovation mindset by the sound of it. Is that fair to say?

SPEAKER_02 4:06

Yes, I think we we we we have really in our DNA all this innovation mindset from the beginning, because at that time uh everything was new. It's clear we had we had the printing industry that started that evolved. There were a lot of trends, more packaging, go to plastic, and it it was really the the start also of all the industry of the packaging industry, and uh it was one of our target, I think. It was not there, but it what I heard to to bring and to bring solutions to the market, to bring uh high speed, to to increase the print quality, to make something that really can work in an industrial field. And and I think this we we we keep in us also today. That means today our DNA is really to make uh strong machines that can have high speed, high quality. Um they work for many years uh to suit to the industry requirements.

Why Direct-To-Shape Is Worth It

SPEAKER_01 5:21

Yeah, and I can see that 1962 really links with the consumer kind of good boom, if you like, suddenly disposable incomes, more um products readily available. I can see that as a pivotal year also for the for the world, really, in terms of consumer growth and stuff and disposable income. So that makes a lot of sense. Um still, though, the leap from newspaper to direct-to-shape, in essence, it's like sounds difficult technically to me, to both both different customers, different um different technical processes. So um from the other days, polytype focused on direct-to-shape decoration rather than perhaps flat labels or sleeves. What why is it you chose that technically difficult path? And how has that perhaps shaped your leadership today?

SPEAKER_02 6:18

Yes, I think I think you are completely right. Uh, at the end, direct-to-shape it is the hard way. But but on the other side, it's also the most powerful way to create impact on the packaging. Uh, because uh for us, the decoration becomes part of the object, it's not something you you add with a label or another process, it's really directly on the shape, and it's not easy, make everything difficult, but at the end, we are convinced that's the best way and the best quality uh for the end product. Um, what we need, we if you go a little bit back, I said before, polytype originally started by printing on aluminium tubes. With with that kind of product, you you need to print directly on the shape. You you you it's it's difficult to have another process. And that from the beginning, it was a clear choice for us, and it's a path we have continued to follow ever since. And I think we will continue to follow it uh in the future because this is at the end our DNA to make high precision engineering uh for for the industry and the printing industry. Um, but it's clear to be able to make direct to shape printing, uh, it needs a lot of manufacturing expertise, precise control of registration. Uh, we need to know a lot about the surface, the handling, the curing. Uh so it's it's not only making a printing machine, it's also to have all the process know-how. And this is exciting for us and our employees and our customers. Um, but I'm really convinced that direct to shape will continue to play a very important role in the future of the packaging industry, uh, driven by new regulations such as the shift toward monomaterial solution, that's also a big trend, uh, as well as increasing demand for flexibility and and on-demand production, like we are doing with within Jet. So this direct to shape bring you really a lot of advantage that we really want to continue to bring on the market.

Dry Offset Strength Meets Digital Growth

SPEAKER_01 9:03

Yeah, it's an exciting evolution. I can see there's clearly an evolution there, and I know you obviously back in 62 when you began, it was all about um analogue in the director shape space. And and and I believe Polytype remains a leader in dry-offset um and continue, don't you, to launch new high-speed machines? Um, and the experience that you clearly must have gained over that time perfectly positions you. But how how do you balance really your analogue excellence with digital transformation? Because you mentioned Inkjet there, and obviously you're kind of one of the early adopters of Inkjet and so on. How do you balance the two? Yes.

SPEAKER_02 9:47

Yes, uh, it for us uh dry offset is still a major activity for us. Um, and every year we continue to invest in this technology, to introduce new features that increase both productivity, print quality. Just for an example, with with our new prime offset printing units, we have taken a significant step forward in print quality, offering new decoration possibilities to our customers while maintaining high productivity. This technology is now available for both our main product, that means on plastic and on metal application. Um, so that means dry offset remains the best printing technology for large batches, high speed production, and cost sensitive markets. But as you say, at the same time, we do not see dry offset and digital as being in conflict. We see them as complementary tools in a decoration toolbox. Uh, digital printing is not directly competing with dry offset. Uh rather, it's bringing new possibilities on the market. In fact, most of the digital printers we have sold uh during the last year went to new customers, not existing customers. So we bring new solutions that gives opportunity on the market to make new products, new business model. Um and and I think this is important. This is we really want to follow both ways, because for the moment they are completely other um, yeah, I advantage. Every technology has other advantage, um, and and so we will continue to develop both and to promote both because uh the market is is requesting this.

Building The Kalmar Digital Ecosystem

SPEAKER_01 12:02

Yeah, and that's good to hear because uh you know obviously analog has a place. I think many people misconceive that perhaps digital is a replacement technology to analog, and clearly the kind of fast-moving pace of the packaging industry and the sheer scale, analog will always have a position, I would imagine, that is strong, but actually the DNA of digital attached to that, but not as a replacement. So that's interesting to hear that you're gaining new customers for the digital that are not just existing legacy customers for your analog, suggests that the market's changing, but that people are seeing digital as a and understanding the opposite the proposition of digital as well, which is which is super interesting. And and I I'm aware obviously that Polytype really sort of embraced digital when I say digital, digital inkjet in 2010, and you really continue to evolve and improve and enhance that uh investment with as the technology evolves, right? And improve improves and so on. Um but also it's not in always just about the inkjet, is it? It's about the digital journey attached to it. Um so so with that in mind, really, uh you've talked before about a digital ecosystem. So it's it's not just the inkjet, it's the software automation, flexibility of the printhead. What makes that approach different to perhaps others in the market? Because I think that that's worth sharing, isn't it?

SPEAKER_02 13:48

Yeah, I think this is the most important thing, and I appreciate really the question that you had. Um we we started our digital journey about 16 years ago, so long time for Injet. Um for us, uh, it was never just about adding injet to our portfolio. It was more about building a complete ecosystem with hardware, software, electronics, automation, processes, know about the process, the service behind, because it's all also really important. All designed specifically for the direct-to-shape printing. So it was really to think at 360 degrees. I think a key differentiator is that PolyType developed uh today its and and from the from the start, its own inkjet technology platform called Kalmar. Uh, Kalmar includes the user interface, the data processing software, all the network technology, printhead, driving electronics, and and all the ink supply management. This means we control the full technology stack and can continuously involve the system to meet industrial requirements and at the end the direct-to-shape requirements. Uh, we we also supply our printing system to other integrators. So that means it's not only the development, it's not only for Polytype, it's also for other customers. This pushes to stay competitive and flexible and to explore new opportunities. Our OEM activity is a bit, I would say, like Formula One. So we it allows us to develop high-hand features that we can later in this trial lies in our own machines. It also helps our engineer to stay connected with what is happening on the market. Uh so it opened our eyes, I would say. And uh since the beginning, it was also really important for us to try to create some collaboration with with high schools. And and we had the opportunity to invest uh with with uh with our partners in the iPrint Institute at the engineering school in Fribourg, um, that now is well known around the world and help us really to improve uh our processes, and it's also really important because uh then we can hire some engineers from them so they can learn and then come back to us. And the majority of the team today is is coming also from this iPrint Institute at the engineering school. So, what makes us different in really I think these three things that means the the internal development of our own digital technology platform, our OEM activities, and our strong partnership with University and Research Institute. Um and perhaps another aspect that may be different is that we do not sell ink by ourselves. This is, I think, also quite different comparing to other companies. Instead, we we recommend ink suppliers who produce what they have products and ink that are compatible with our system, but customers purchase the ink directly from them. We believe this open approach creates uh healthy competition in the market and helps also keep ink affordable by removing intermediates and ultimately support the adoption of digital printing machines. Because one of the major targets that's still often on the table is the cost of the ink in the digital world, comparing to dry offset and and other printing technology. So, our target is really that at the end um we we deliver machines, the customer can buy the ink where they want, and this I think is also a significant difference comparing to some of our competitors.

Beyond Packaging: OEM And Aerospace

SPEAKER_01 18:34

Yeah, what you've explained there, really interesting um to learn more about, I guess, the way you're approaching it with the software beginning there, really sort of strategically, isn't it? It's kind of uh strategic solutions as opposed to a tactical purchase. Um, you're actually investing in that. And I like the um the kind of open approach, like you said, that you you work with other OEMs and so on that can benefit from your technology, and you see the value in what that provides you in terms of insight, information as well as business, of course. And the fact that it's an open system with different ink providers, that too is quite different. Again, it's an open strategy. You use that word yourself, it's positive. Also to have that connection with the university and the the next generation of engineers and innovators to embrace that um that kind of open culture that you have there, which is um sounds really sort of positive and and um and flexible as well and gives you that agility, doesn't it? Um obviously you're famous in the world of packaging, aren't you? But um technology such as digital enables, I guess, one to move beyond their markets and so on, and of course that's in your DNA to an extent. Um I believe your digital ecosystem now extends beyond packaging, perhaps into other sectors. Um explain a bit about that. What is and how digital has enabled perhaps some new new possibilities both for for polytype but for um the inkjet technology itself?

SPEAKER_02 20:11

Um yes, I I I think I think digital is is is is a really important uh technology in in the packaging uh industry because it allows really to bring new product on the market, new business plan on the market. Really, this on demand uh to reduce also all the stock to the the size of the of the batches, and and uh it helps really to give to our customer the flexibility, uh creativity uh at the end, uh, but it's clear it it needs to be reliable, all the value chain needs to be easy, and this is also one point that it's important for us is not only to give a machine, but we also try to give the complete solution. That means perhaps from the web shop we have also some solution where we could go and deliver a web shop, the customer can make some uh customization, and all the information goes directly to the printer, and then we have also some connectivity directly with uh with uh the supply chain. So the target is okay, digital brings new possibilities, but we need also to think around these possibilities for the integration, and that's that's really important for us to be a part and entire part of all um the value chain.

SPEAKER_01 21:50

Yeah, that's that's integral so that you understand the the challenges but also the opportunities, because there are many, and um it's it's taking the right one. And I believe some of your technology is used outside of packaging as well. Is am I correct? In other segments like aviation?

SPEAKER_02 22:07

Yes, exactly. We we did with our OAM uh activities, we had the chains to make a lot of different projects and uh from automotive uh to different types of goods that need to be printed, like puzzles, for examples. Uh, but we did also some projects for the aerospace uh industry. So it's clear we we are quite open. Where we need to where something needs to be printed, uh, we could help to to achieve this uh this target.

Global Manufacturing And Service Support

SPEAKER_01 22:41

Yeah, yeah, and and and that opens an entirely new vista of opportunity, doesn't it? And um deploying the same principles in essence and transferring them in different ways. And um I think that's uh that's critical. At the beginning, you mentioned about Swiss precision. It is a famous uh perhaps characteristic of Switzerland and Swiss made products, is is that precise um nature of things. But you're actually quite global, aren't you? You're a global business. Um give us a feel for your kind of global reach and you know the perhaps some of your facilities and teams around the world, but um which which also is helpful, isn't it, in terms of service, you know, access to spare parts and so on. And that must really help to strengthen your overall value proposition.

SPEAKER_02 23:36

Yes. Yeah, we have the chance to be present around the world um in order to stay uh as close as possible to our markets. I think this is really important. Um today we build complete machines in Switzerland, but also in Thailand. Um and and we maintain uh spare part stock in in three main locations. So we have really a lot of spare parts in Switzerland, in the United States, and also in Thailand, which allow us to be very responsive to our customers because uh we think service it's it's uh it's important and Polytype is well known for its service, uh, and it becomes more and more important in also in the digital world, because some of our new customers start only with one machine, uh so they they they rely on fast and efficient support to resolve any issue uh as quickly as possible. So they are our service is not only our machine needs to be good, but the service and we need to be fast at the right place at the right time. Um, so we have highly dedicated and passionate employees who understand uh how critical service is for our customers. Today, service is just as important as machine quality. We we also have in-house manufacturing capabilities, so we we decided to maintain these capabilities, which allow us to produce spare parts very quickly, even for really old machines. So we have machine 30, 40 years in the field, and uh we are still able to manufacture these parts in-house or with partners. Um our customers know that when they buy a polity machine, they gain access to a strong global service organization that will support them in any situation. And uh at the end, I can only say thank you to the service team because they did a great job, and I think our customers are appreciated our service.

The Next Decade: Sustainability And Automation

SPEAKER_01 25:54

Yeah, and that's important, isn't it? Making a big capital investment in machinery and technology. As you said, the new the new customers may have one machine, or it's but it's critical, it's super critical to their business. Having that additional support and help is pivotal, I would imagine, on final decision making to make that make that investment. It's really important, isn't it? Um looking into the future, really, with with an agility in a in a in a very uncertain world that we live in now, and I guess in a time of rapid change and some of these trends coming through very strongly, like sustainability, customization, digital adoption, uh mixed in with global. How do you see polytype perhaps evolving over the next five to ten years?

SPEAKER_02 26:46

Yeah, it's it's not easy. Yeah, it's why today we are facing a lot a lot of geopolitical uncertainties and strong competition in some markets, mainly also from Asia. Uh to build machines in Switzerland is not every day easy, but uh but I think we have success and we will continue to have success. Uh, that means we may we remain confident that our strength and and the investment uh we are making will allow us to continue on a successful path. Uh we will continue to invest significantly in the development of our digital printers, because I also after 16 years, I think we are at the beginning of the journey. We are constantly uh training our digital technology platform and expanding our machine portfolio with new with our new printing system. So that means we we go step by step. Uh now we have a new, really a great new printing engine, and now we bring this engine on the different machine from our portfolio. Um we also believe that digital printing can contribute to reducing waste and making the packaging history more sustainable. But on not only the inkjet, we for example, in parallel, we are also developing new solutions to reduce the amount of plastic used in the packaging. For example, uh, with our new shoulderless technology, we enable manufacturers to use up to 50% less plastic when when producing and extruder tubes. So we see that with new technologies, new ideas, innovations, we can also bring something uh more sustainable uh also in the plastic industry. And and at the same time, we will continue investing in smart industrialization, including a system with AI, automation, and we see that one pain of our customer is also to have the right operator on the machine. So we we really want and we really invest also in automation, how we could make our machine uh runnable with with less operators. This is really one also one of our focus. And then we need to be careful because uh a lot of regulation will also be reshaped in the packaging industry, uh, but we believe they will create new opportunities also for us. So we are also really watching on on the new regulations. And uh in this uncertain and rapidly changing environment, I think the key is to remain flexible and and and continue to innovate. And I think this is one of the strong parts of Switzerland is to be able to bring innovation uh on the market in the industry, and uh we need to invest a lot in this direction.

Culture, Leadership And Closing CTA

SPEAKER_01 30:15

Yeah, and I I I think that's what I've um Switzerland is a is an area that is precision on the one hand, but quite very innovative on the other. I think that that mix is uh we're seeing a lot of uh great innovation come out of Switzerland have done for the last uh 10 years in a in now uh in this space, and Polytype is a a great example of that. And I think, like you say, the flexibility is is critical among that. Um just wrapping up, really, I guess you're the CEO of Polytype, uh dynamic growing business, global business. Um I guess the thread of the conversation that we've already talked through the past um 20 minutes or so, I can I can gain a pretty good understanding of the DNA and that. But you, as the kind of leader of the business, a little bit about maybe about culture and leadership. How would you describe Polytypes internal culture and how does leadership, collaboration, and openness drive innovation throughout the business?

SPEAKER_02 31:20

Yeah, well, I mean it's to say first, um, we we are really fortunate to work in a company that has a a long-term vision that that helps a lot, uh, where employees are are uh truly at the center and play a very important role. Um so that's that's help us really to think for tomorrow, to see the goal, and and it's important for the management, but also for all the employees. Um at the end, our success today is built on know-how, experience, patience, collaboration, and innovation. So we say polytype, uh patient, innovation, decoration. That's our motto at the end. And uh our goal is to create an environment where our employee can grow and develop with confidence. Uh, for me, the most important things are communication and teamwork. Every employee should be able to bring new ideas that help improve our efficiency or our products and at the end bring to innovation. Um, as a Swiss company, we also need to create the right framework and the conditions to promote innovation and high quality. Uh, this is our own only future. So I need to have employees that are really motivated and uh they have they have passion for what we are doing because it's not every day making machine, making service, bring innovation. It's not every every day easy, but uh as a team, I think uh we did really great things, and uh that's that's really important that we work together and we try to make everything that we can to bring this filter and this leadership uh in this direction, yes.

SPEAKER_01 33:24

Yeah, well, um it sounds very exciting. I love the flexibility, the open strategy, the um adaptation, and the willingness to try new things and moving out of your comfort zone together, but towards a vision that is long term is great because so many of um the uh uh businesses in the world that are focusing on quarters and quarters and quarters, but and and I think that sometimes loses the essence of the purpose of the business, the culture of the business, the the fact that actually what makes the difference in the business is the people is the people, like you've said, the passion and the motivation, the mindset of the people has to align, but that together you succeed, and I think that's a great way to perhaps um finish this podcast. And I really appreciate you making the time today, Julian, to join us. It's been super interesting listening to your story of the story of Polytype, and we're excited to be working with Polytype going forward and creating more content. So thanks for joining us today.

SPEAKER_02 34:26

Yes, thank you so much, Marcus. It was a real pleasure for me, and uh we also uh are happy to create more content and share with uh with your community our uh uh different project and uh success. Thank you so much. Thank you.

SPEAKER_00 34:45

Thank you for listening. If you enjoyed this episode, you can subscribe now for more great audio content coming up and visit futureprint.tech for the latest news, partner interviews, in depth industry research, and to catch up on content from Futureprint events. We'll see you next time on the FuturePrint Podcast.