Converters must consider a wide range of factors when investing in a new flexo press. Everything from automation to the press operators must be analyzed.

The investment process is as critical as ever. Presses have been designed to accommodate a host of functions, many of which may be new to a vast array of printers. Manufacturers are ready and willing to help label printers navigate the daunting task of making a capital investment, though.

With new technology comes greater potential for enhanced ROI. Manufacturers are increasingly designing presses to fit the specific needs of each customer. Nilpeter, with North American operations in Cincinnati, OH, USA, offers a lineup ranging from 13” to 26”, which can be tailored to fit the unique applications of the converter.

“The modern press is based on a very simplistic mechanical design and driven by multiple motion control motors,” explains Paul Teachout, vice president of sales and marketing, Nilpeter USA. “There is now full automation through digital controls, saved data and feedback. The great thing about automation is that it provides feedback on performance and history. This makes presses much easier to troubleshoot, maintain and more cost effective for total cost of operation. Yesteryear's presses were 80% mechanical and 20% software, whereas modern presses are just the opposite and provide years of consistent higher performance with a lower operating cost.

“We feel automation is the new Lean, but there is a fine balance between automation and human interaction that provides the desired results,” adds Teachout. “Our presses are designed to engage with a modern-day workforce, raised on disruptive technologies and wireless clean-hand controls. This is what will attract the workforce of today to maximize the efficiency of the investment on both the automated and human level.”

In the case of Nilpeter, its new FA Line features an intuitive user interface and fully mobile print controls. The FA’s Clean-Hand Technology minimizes hands-on press interaction and enables clean hands during press operation. In addition, all data is saved, jobs are easily recalled, and the press will auto register. The modern flexo press has been designed to eliminate previous manual controls.

“[New technology] also has a major impact on the total cost of operation over the life cycle of the machine,” says Teachout. “No longer do we build presses with gear drives, line shafts and gear boxes, with all the associated maintenance and assembly it takes to maintain them. These are all added costs.”

By incorporating more data, the goal is to improve the ROI. Printers will need to perform a thorough cost-benefit analysis to determine how the press meets their workload demands.

“We can no longer rely on the craft to see us through,” says Teachout. “We must run our operations and production by the numbers, then apply them to an automated platform for predictable and repeatable results. Like anything else we use in our daily lives, the press is now a computer that performs a function. This is the generation of Internet of Things and clean-hand technologies. Presses have evolved from very mechanical machines that required a specific skill set and a little bit of vodoo magic to be productive. Those days are gone, now it is very common to replace that old mentality with new and innovative thinking. The current technology will easily replace two older presses and be more productive. This not only improves my bottom line but cuts my workforce challenge in half.”

The modern flexo press is also modular, meaning that it can grow as a converter’s business grows. When investing in a press today, converters do not need to worry about obsolescence after a few short years. The equipment can be added on to, allowing businesses to bolster their bottom line.

“The modular construction in both mechanical design and software makes adding new innovations much easier on a new platform,” states Teachout.

While flexo presses have made the leap into the next decade, there are other investment factors. Digital assets might make sense for some converters, while a hybrid press – with inline capabilities – could provide a printer with the best of both worlds.

“The digital and flexo worlds have definitely had an interesting journey together,” notes Teachout. “We have seen much growth in the requests for hybrid solutions, where the two technologies can complement each other. Hybrid technology takes advantage of the short-run, speed-to-market nature of digital while having the ability to convert and embellish inline. Having the strengths of flexo before and after digital systems allows both processes to thrive in a single platform, and the converter can take advantage of the most cost-effective asset for the application. It all comes down to the product mix and market you are entertaining to determine the fit that is most rewarding for your operation.”

When considering a new press, Teachout adds, “The cost of new technology is much more affordable than ever before.”