Greg Hrinya, Editor11.11.21
Digital label and package printing may have originated as a niche technology, but that is no longer the case. Digital is big business, and now many converters are even building their entire portfolio around this printing technology.
Now is the right time to be in the label printing business, as the industry’s inherent value was on full display during the Covid-19 pandemic. More brands than ever before are requiring labels, especially smaller craft brands or big brands with countless SKUs. The latest printing trends are tailor-made for digital printing.
“Label converters, for the most part, are enjoying a sustained boom in business because long-term trends in consumer behavior accelerated at warp speed during the pandemic,” states Victor Gomez, director of Industrial Labels, Epson America. “Consumers working from home, or hybrid, have turned to e-commerce for many purchases they would have made in person before. These shifts in behavior are well served by digital printing because of its ability to deliver short runs quickly and profitably.”
“During the pandemic, it really has highlighted, more than ever before, the importance of being quick and nimble,” says Bill Myers, marketing manager at Domino. “And digital printing provides that ability, benefiting both converters and brand owners. Converters have been able to produce labels in a very quick and highly productive manner. And brand owners have been able to change their market and brand messaging at a moment’s notice.”
Lightning Labels, a digital label converter based in Denver, CO, USA, relies on the high-quality output, quick response and fast production cycles afforded by the technology. With demand peaking during the pandemic, Lightning Labels’ digital e-commerce platform has allowed customers to print short or long runs for several versions, easily and consistently.
“With container shortages an ongoing issue and concern, we offer low minimums of 50 labels per version, for as many versions as necessary, up to several hundred,” explains Gary Paulin, Lightning Labels’ vice president, sales and client services. “We can quickly accommodate 100,000 quantity runs as necessary. This flexibility is critically necessary during normal times, and even more so now during these uncertain times. We ship most orders in 24 hours, and for most larger runs in 5-7 business days. Consumer demand is also very high at this time and driving the urgency in varied types of orders in virtually all product verticals.”
According to Eli Mahal, head of marketing for HP Indigo Labels and Packaging, one key trend during the past 18 months was the shift of volume from conventional presses to digital assets. The production flexibility and application versatility has spurred converters to invest in digital, in order to produce jobs in the most effective way possible.
“A few notable trends that we’re noticing are the upswing in online business through e-commerce and web-to-print,” says Mahal. “Digital printing is also enabling converters to streamline production by keeping traditional machinery dedicated to the very long runs and diverting more production to digital printing.”
Lightning Labels, which has partnered with HP, expects to see digital converters compete more frequently with long-run flexographic providers while also seeing increased demand and longer runs per version.
“When considering the variety of papers and films we offer, and the multi-version control that is most affordable with our 100% digital platform, in terms of not passing on setup fees or upcharges to our customer base, the prime label digital market will continue to expand and grow exponentially for many years to come,” remarks Paulin. “We see increased competition every year and welcome it. We love what we do and how our customers love working with us, and competition further highlights our expertise and experience over 20 years.”
The e-commerce surge has created an immediate increase for pre-printed barcode labels in the logistics supply chains. “Domino customers have seen a 40-50% increase in demand for variable data labels, and I believe the trend will continue,” states Gary Peterson, senior account manager of Variable Data Printing Solutions at Domino.
Converters are looking to optimize digital’s capabilities, both in terms of customization, individuality and enhancements. Donna Covannon, Xeikon’s director of marketing for North America, notes several other critical trends. “Converters are adding embellishments and tactile elements to their labels,” she says. “And variable information, be it for uniqueness or as added security features for anti-counterfeiting and traceability, are also rising in prevalence. Improvements are also seen with color management features to ensure the right color is produced the first time and then every time afterwards.”
Travis Pollard, vice president and general manager of ASL Print FX, says, “Every label that we print is its own custom project. It can require foil stamping or embossing or variable data or sequential numbers, and we have the tools to do that with our MPS EF Symjet ‘powered by Domino’ hybrid press.”
Each iteration of press technology is improving upon its predecessor with a host of new functions and capabilities. “In general terms, each year sees faster and higher resolution technologies incorporated into the available digital printers,” notes Jay Larsen, general manager/director of R&D - Digital Hardware for INX International Ink Co. “These incremental improvements are important. However, changes to workflow, integrated finishing and variable data, and variable finishing (cut, varnish and more variables per label) are true leaps in capabilities and productivity for those customers who adopt them.”
There are numerous options from reputable manufacturers, and these presses and printers can be found at all price points, with a variety of options for speed, print quality, web widths, embellishment and color gamut. When selecting a technology, be it digital or flexo, there are several factors to keep in mind.
“Digital presses are already producing sellable product in the 160 fpm range,” explains Gomez. “What is the incremental benefit to the converter of even more speed to rival their existing – often already fully depreciated – flexo presses? What is more important to the business owner isn’t burst speed but throughput. And that entails a host of other production issues that don’t usually make it to marketing pieces such as uptime, maintenance routines, and ease of use. If the mechanism for higher linear speed entails adding more complexity to the system – more printheads, for example – the overall benefit is actually much smaller. Something similar applies to resolution. Does a race to higher dpi result in better looking labels? Does a higher dpi matter if it gets lost in the viewing distance of the typical consumer when picking up a product from a shelf?”
One of digital’s greatest attributes is its speed to market. For example, HP has developed The Digital Label Factory, a full, end-to-end ecosystem that gives label converters the agility to thrive in today’s fluctuating markets. HP has designed a blueprint for customers to move from “next-week” to “next-day” delivery, with less labor required and higher Overall Equipment Efficiency (OEE).
Manufacturers have responded to this demand by further enhancing their digital portfolios. HP has unveiled a range that includes the HP Indigo 6K and 8K digital press for narrow web labels, the HP Indigo 25K for mid-web flexible packaging and labels, and the HP Indigo 35K for folding cartons. The other key areas are enabled through a combination of hardware, PrintOS solutions, the new DFE, and new inks.
Epson, meanwhile, has teamed with several important partners to add inline finishing and inspection solutions for its SurePress L-6534VW UV digital label press. This allows converters to choose the production solution that works best – finishing inline or off-line – as their job types and run lengths require.
The rising adoption rate of digital printing will not slow down, either. In fact, Xeikon diversified its digital business in anticipation of future printing trends. Xeikon offers its Cheetah 2.0 dry toner technology, as well as Panther 2.0 UV inkjet technology. The presses are also equipped with the latest automated features. The company offers a wide range of color and workflow services, too, highlighted by its X-800 Digital Front End (DFE), which unifies every facet of Xeikon’s portfolio.
“Earlier this year, we introduced two new models: the CX30 and the CX50 entry level dry toner presses,” says Covannon. “It’s important to note that with each cloud-connected solution, operators can monitor print manufacturing from anywhere on the shop floor by viewing the interfaces/dashboards – 24/7 on a smartphone or any other device.”
That drive for versatility led Dantex to launch its latest product: the PicoColour 254HD digital press. With the addition of PicoColour 254HD, the Pico range now covers five different UV inkjet digital presses: the popular PicoColour 210 Classic, PicoColour 254HD, PicoJet 254, PicoJet 330i (164 fpm, 50 m/m) and the flagship PicoJet 330S high speed model, operating at 250 fpm (75 m/m). All PicoJet and PicoColour 254HD digital presses offer a 2.5 pl dot size and resolution at 1200 x 1200 dpi.
“Our new PicoColour 254HD is the perfect addition to our growing range. With the market readily accepting inkjet as its future, we have listened to our customers and increased versatility across the portfolio of presses available,” says Ben Danon, CEO Dantex Group. “As an established player in the digital press global marketplace, Dantex continues to address the different levels of demand while maintaining the highest quality standards.”
There are options for converters who want to add digital to their arsenal without incurring the costs associated with a brand-new production press. Colordyne, for example, offers its retrofit technology at a fraction of the price.
“Converters are coming to Colordyne because they are looking for an alternative to purchasing a standalone press,” explains Katelyn Bohr, director of marketing at Colordyne. “Many do not have space on their floor without removing a current asset, so we go in and add digital print capabilities to a flexo press already in their facility. Plus, this allows them to maintain the flexibility of running flexo, digital or hybrid on the same piece of equipment based on the jobs they need to run that day.”
New installations
The Covid-19 pandemic did not stop label converters from investing in new digital printing technology. Hub Labels Inc., a Maryland-based label converter, recently installed an HP Indigo 6K digital press. The digital asset will give Hub Labels increased short-run capabilities across a variety of industries, including food, beverage, and health and beauty, to name a few.
For Thomas Dahbura, president and owner of Hub Labels, the HP Indigo 6K digital press will allow the converter to meet a wider range of customer demands. “Over the last two years, label demand has continued to go through the roof,” he says. “Even with all the challenges facing our industry, the economy continues to be strong. Consumers are buying. In the last year, we’ve seen the greatest growth from our small to medium-sized customers.
“By adding the HP Indigo press to our lineup, we are adding more than 10% capacity to our facility,” says Dahbura. “That’s huge for us and our customers. It helps us balance our workload across our presses, offer shorter lead times, and be more flexible with how we fulfill orders. In addition, the print quality is stunning and the right fit for Hub.”
After installing a Domino N610i digital UV inkjet press, Abbott Label recently returned to the digital specialist for a K600i dual bar digital UV inkjet printer to aid with VDP. “Covid hit not too long after that and now everybody needs labels,” says John Abbott, president of Abbott Labels. “From the QR codes to the consecutive bar codes – and that’s where the Domino K600i came in.”
Mammoth Labels & Packaging, located in Colombus, OH, had been farming out its digital printing work prior to the investment in a Domino N610i digital UV inkjet press. The press, which was installed right at the outset of the pandemic, helped Mammoth grow its digital sales 93% in 2020.
“Our flexo customers were looking to shorten their runs and add SKUs,” says Stuart Reeve, president and CEO of Mammoth. “So, in order to satisfy those customers, we took the work and farmed it out to another digital supplier. The choice to bring digital in-house became very simple for us. With the addition of the Domino, our prime label business grew exponentially, specializing in the wine, beer, and candle industries. The Domino has really given us the flexibility to be able to service those customers.”
That success has given Mammoth currency with its current customers, as well as the confidence to approach new prospects. Curt Powell, business development manager at Mammoth, explains, “I think the thing that the Domino has done for us from a sales perspective is it has really given us confidence. So, when we go in and meet with a new client, we have the confidence to say, ‘Yes, we can do that.’”
Chris Merlick, founder and CEO of Label Solutions, made a similar decision to invest in digital, as his company had also been farming out its digital work. Label Solutions entered the digital printing arena by selecting the Durst RSC-E UV inkjet label press.
“When we first started our digital journey and doing our due diligence, we looked at a number of manufacturers,” explains Merlick. “We sent files to all those partners, looked at samples and subsequently had quite a few meetings with them, and it really came down to Durst and one other manufacturer. Through our testing, Durst really rose to the top. We felt that with the 1200 dpi technology and 2 picoliter ink, we’re able to put down a real differentiator in terms of quality. Given that we’re selling ourselves as a premium provider of labels, that was a big part of it. The 1200 dpi technology and the number of Pantone colors we’re able to match with the expanded gamut ink really drove us to Durst.
“The Durst is a Ferrari in a sea of Chevrolets,” he adds. “As a premium label shop, there’s just something exotic about the Durst technology. It sets us apart from a lot of North American label converters, and we’re always looking for differentiators in this business.
Meanwhile, Nova Label, which is based in Maryland, recently installed Colordyne’s 3800 Series UV – Retrofit on a Mark Andy flexo press. In addition to improved durability on its labels, the technology will allow Nova Label to target markets it previously could not such as craft beer. The retrofit features 4-color process and white, but it’s expandable to seven colors in the future if needed.
“The durability of the UV inks and using standard materials was a big advantage, so I think the future looks really bright for that unit and its technology,” states Alan Rich, president of Nova Label. “For what we need to do, Colordyne made the most sense. They’re a good company, and Taylor Buckthorpe has been great. They’ve answered all our questions, and the technicians know the machinery inside and out.”
Colordyne completely redesigned the print engine for the 3800 Series UV – Retrofit based on customer feedback. The chassis, IDMs and software were all engineered to deliver reliability, ease of use and quality to its customers like Nova Label.
“Reliability was a huge element that our customers were looking for,” says Colordyne’s Bohr. “With supply chain disruptions and a lot of uncertainty in 2020, they needed a digital printer they could depend on. Working with our partners, we were able to deliver a retrofittable print engine that met this expectation.”
Screen Americas also just announced a customer’s expansion into label printing with the Truepress Jet L350UV. A traditional offset printer with a primary focus on folding cartons, Pacer Print and Packaging of Chatsworth, CA, shifted 80% of its label business in-house with the new inkjet press. A regular supplier of labels for the cannabis and CBD industries, the printer soon found itself expanding into the wine, liquor and candle industries during the pandemic. Peter Varady, the company’s founder and president, chose to invest in the Truepress Jet L350UV to meet the demand for additional labels.
A first-time Screen customer, Varady was sold on the reliability, durability and stability of the machine. He was also impressed with the customer service he received and the Trust Network Service program. “The Truepress Jet is a real workhorse, and there is an actual team behind the press,” says Varady, who found the transition to digital printing rather seamless.
Stouse, a wholesale print provider, has diversified its business with multiple digital technologies. In the past two years alone, the company’s digital printing investments have included six presses, most recently two HP Indigo 6K roll-to-roll label machines installed in February 2021 to meet increased demand for food, beverage, and consumer products. In order to fully service its customers, the team also purchased a Xeikon 3500 high-definition, 4-color digital folding carton press and launched a paperboard folding carton line with more than 30 market-driven designs.
In Europe, Nord Technique Etiquetage (NTE), a family-owned company based near Lille, with 35 years of experience in label manufacturing, has become the first company in France to install a Bobst digital label press, the Mouvent LB702-UV. It is the second investment in a Bobst machine for the company after it purchased a Bobst M4 inline flexo press in 2016. The investment in digital printing is in response to an increased demand for shorter-to-medium length runs.
Now, according to Thibault Duponchel, general manager at NTE, the company is “perfectly placed” to take on whatever combination of jobs come their way. “Since owning the Mouvent LB702-UV, I’m proud to say I now have a fully optimized production floor by being able to offer the very best technology for all print jobs,” he says. “We’re using flexo for the very long runs and the Mouvent digital press for the rest. It’s clear that with an ultra-quick and productive machine like this, digital is not only for short runs anymore. It’s the perfect tool for short to medium runs, and I am now shifting all jobs of several thousand linear meters to digital.”
Pandemic-proof
The challenges associated with the global pandemic magnified the inherent value of digital printing. Brands needed labels and they needed them quickly. Digital printing presses were able to help meet demand for shorter runs with quick turnaround times. These capabilities led to an influx of digital investments throughout the pandemic, notably from the aforementioned Hub Labels and Nova Label. There were a multitude of other label converters that turned to digital during the uncertainty of Covid-19, too.
“During the pandemic, demand for labels for essential products showed a pattern of strong growth during each wave of infection, followed by de-stocking and re-stocking based on the change in infection rates,” explains Xeikon’s Covannon. “This meant printers and converters needed to be on-the-ready to deliver quickly. For instance, when complementary industries, such as distilleries, turned their operations into making hand sanitizers, they needed labels quickly and affordably. In some cases, they also needed to maintain their brand integrity in these adjacent product label designs. Digital printing enables the short runs and fast turnaround times, especially if there are required design changes.”
“The pandemic has caused a change in several supply chains, with consumers shopping more online than ever before for products and delivery services,” says Marco Zanella, global business development director - Inkjet, for INX International Ink Co. “This has created an increased demand for printing solutions that are more versatile, easily adaptable to variable conditions, and suitable for smaller and diversified demand. Digital printing is made to meet these requirements above others, and we have seen an acceleration of the development and rollout of solutions for printing and decorating items for a large variety of applications.”
For Lightning Labels, the all-digital label converter had contingency plans in place to accommodate the rise in customer demand. This goes hand-in-hand with the flexibility that digital printing offers.
“While it has been challenging to keep pace with demand, we have tooled for it, added skilled staff where needed, and improved our online order portal,” states Lightning Labels’ Paulin. “Additionally, we have ensured consistent inventory levels for the wide variety of papers and films we offer to meet the longer run needs while we’ve seen our competitors struggle to do the same. We continue to innovate and adapt quickly to current market conditions and customer demand.”
According to Colordyne’s Bohr, the pandemic accelerated many of the trends taking place prior to quarantine. “One of these trends includes the adoption and use of digital printing equipment,” she comments. “We all experienced uncertainty and supply chain challenges, which highlighted the efficiency, flexibility, and on-demand benefits that digital printing provides.”
The workforce challenge was also on full display during the pandemic, as many converters and suppliers struggled to attract and keep employees. The inability to hire and retain skilled workers further lends itself to digital’s best attributes such as automation.
“One of the things that easily gets overlooked that digital printing technology has done for the industry is help with workforce development, especially for converters who are trying to attract the next generation of workers to their business,” says Domino’s Myers.
“The printing industry was having trouble replacing retiring pressmen even before the pandemic,” notes Epson’s Gomez. “While younger workers don’t want to spend years in apprenticeships learning how to run a flexo press, digital presses are much more familiar to them, making training easier and shorter. In addition, the automated features of a digital press, like Epson’s SurePress, means a single operator can run multiple presses at the same time. Converters appreciate being able to add print capacity during business spikes like we saw last year and not have to worry about headcount.”
Xeikon has announced version 2.0 of its Panther UV inkjet technology with the launch of two new label presses: the Xeikon PX3300 and Xeikon PX2200.
As the company’s wide portfolio evolves in line with advances in technology, the new presses, which are replacing the existing Xeikon PX3000 and Xeikon PX2000, feature advancement in two areas – applications and building blocks – to digitalize print manufacturing. The new presses are now commercially available in Europe and North America.
Filip Weymans, vice president of marketing, states, “We are defining a pathway to full digitization of print production and manufacturing. Responsiveness has become key for any business and can only be achieved effectively by digitalizing all print manufacturing processes and not just printing. The foundation for a digitalized environment lies with collecting data in a digital manner. The data volume, captured in real time, creates the information that is required by label converters to make fact-based decisions. Another aspect is the interfacing connections in production between machines and operators, helping to transfer job information between the different production processes or drawing the attention of operators when it is really required. The cloud-connectivity, machine-machine and man-machine interfaces of our UV inkjet presses will enable label printers to take operational excellence to the highest levels. They offer great potential to maximize OEE, increase sustainability and make an operation robust for any future challenge.”
The new Panther 2.0 Series also offers new opportunities for label printers to expand their applications portfolio. Xeikon’s new substrate handles technology features a new splice table, web detection capability and cooled roller at the curing section. This makes it possible to print high-quality labels on a wider choice of substrates, including clear-on-clear facestock, which requires a high-quality opaque white to make the design stand out.
Both presses can be configured with a fifth print station for white ink and can print on a wide range of self-adhesive media, in addition to clear-on-clear, including coated paper, vinyl, PP, PE, PET, and metalized.
The Xeikon PX2200 and PX3300 presses leverage the advantages of dedicated PantherCure UV inks, which meet the demands from brand owners for high-gloss, durable labels with high scuff resistance. The Panther DuraCure UV technology produces high-gloss effects and stands out across the widest color gamut while delivering enhanced long-term durability for multiple applications such as industrial, chemical and household labels, as well as high-end labels for the premium beer, spirit, beverage, and health and beauty market sectors, the company says.
Driven by the Xeikon X-800 digital front end (DFE), the new Panther UV inkjet presses offer consistent print quality in combination with excellent productivity. The cloud connectivity is achieved through the X-800, providing access to both machine data and job data such as ink consumption, printing time and so on. The latest generation of Xeikon’s X-800 enables custom applications on the Panther series such as haptic printing. This tactile layer of white delivers the sought-after embellishing effect inline with full color printing for designing labels with enhanced tactility and luxury feel. The technology also features variabilization, starting from black and white and going to color numbering and to the most complex full color variable data application through Xeikon’s new Vari-One option.
The Xeikon PX30000 is available with six (CMYKOV) or eight (CMYKOV+WW) print stations. It will now be accompanied by the Xeikon PX2200, 220mm wide, available with four or five print stations, and the Xeikon PX3300, 330mm, available in four and five print stations or 5C-high capacity. With high-performance levels and low-energy consumption, Xeikon’s Panther Series of presses are now equipped with cloud connection and next-generation HMI. This helps operators monitor the workflow to maximize productivity by avoiding downtime and bottlenecks and make changes on the fly while maintaining full color control.
Weymans concludes, “Xeikon’s UV inkjet presses can address any request from label converters. This can mean replacing an older UV flexo press to be more effective, being cost competitive within the high-end to medium-run label market, expanding the digital application space of existing liquid toner businesses, or providing entry-level investments that allow any printing company to embark into the digital label space. By being part of Xeikon’s broader label portfolio (press, consumables, workflow, converting, embellishing, services), converters can over time expand their investment in width and color, or expand their workflow capabilities with ERP or MIS systems. With over 30 years of experience in digital innovation, Xeikon has a deeper understanding that enables them to offer not only the latest innovations and technologies but also a full suite of support services.”
A digital future
While flexography still accounts for the majority of printed labels, anyone perusing this magazine can attest that the number of digital press installations is skyrocketing.
“Moving forward, we expect to see the continued adoption of digital, but in a way that complements the converter’s existing flexo production,” says Colordyne’s Bohr. “Flexo printing isn’t going away any time soon, but converters are looking at how to add digital print into their business. Having options on how to add digital capabilities, from standalone systems to retrofits, gives label converters the ability to choose which method is best for their business.”
More and more brands will recognize the value that digital printing presents, especially on crowded shelves. This will lend itself to even more digitally-printed projects in the future. “Brand owners are realizing that in order to connect with consumers – to gain and maintain consumer mindshare – they need to differentiate their products on the store shelves and create brand differentiation,” says Domino’s Myers. “And one of the key ways to do that is through labels and packaging. That fits right into the wheelhouse of digital printing. Being able to easily provide variable data, personalization, quickly print shorter runs with more SKUs, etc. And the converters who have digital printing will win that business. Those who do not will get left behind. So, digital printing will continue to grow exponentially in importance, and it already has.”
Hybrid printing will also play a significant role in digital’s adoption in the future, especially as many major manufacturers of both digital and flexographic equipment have teamed up to offer robust solutions to the industry. According to Dave Medlar, vice president of Digital Business Unit, Mark Andy, whether it be strictly digital or hybrid, the technology truly represents the future of label converting.
“When Mark Andy first got into digital, especially with my background in engineering, there was such a desire in the market for a digital product,” says Medlar. “We felt like we had to transform the business over time to digital. Eventually, even if it’s 30 years from now, some 90% of the presses in these label converting plants will have some sort of digital capability.”
The benefit of inline finishing will satisfy many converters’ digital needs over time. Currently, many standalone digital production presses require off-line finishing units.
Digital printing is not just a talking point at Mark Andy, either. To better serve this growing market, Mark Andy has added nine individuals to the company over the past year to support the continued development of its Digital Business Unit in the US and Canada.
With well over 250 digital hybrid placements in the region, significant year-over-year sales increase, and the recent expansion of its digital hybrid portfolio with the introduction of Digital Series iQ to the Digital Series family of products, the company has invested to ensure even more successful results in the future.
“Mark Andy is seeing tremendous interest in digital printing,” notes Medlar. “Nearly all businesses that we have talked to in the label and packaging market have seriously looked at and/or have already acquired some form of digital printing machinery over the last several years. Our customers are looking for digital hybrid printing machines that are able to offer the best quality print, are highly productive and easy to operate. Based on all the feedback we get from customers and prospects, we expect continued high interest in digital hybrid printing going forward.”
Even as digital becomes more commonplace, there will still be a place for all technologies, notes Medlar. “Flexo and digital absolutely complement each other, because every label shop has jobs with different run lengths,” he explains. “So, why choose between flexo or digital? The decision-making process comes down to your cost to print or your ROI for that piece of equipment, and one of the key factors is run lengths. Every label shop is going to have long runs with more and more specialization and regionalization of their products. Some of those run lengths, even when producing the same type of label, require the need for shorter runs, and digital helps complement that activity at your business.”
In addition to digital’s flexibility, the technology is also helping promote environmental friendliness in the industry. This will continue to be a pressing topic going forward. “Sustainability is hugely important within the label and packaging industry,” states HP’s Mahal. “All HP Indigo digital presses are designed with the environment in mind. Not only are they manufactured carbon neutral, they also offer reduced production waste and energy efficiency, and support eco-certified materials, including sustainable primers, varnishes and adhesives. HP Indigo is working with its many partners in the ecosystem to deliver solutions that support a circular economy, conducting testing and validation for recyclability and composability.”
HP also envisions a changing mindset toward digital printing. “Our vision for the label industry is a shift to an Indigo-first mindset, which means that an incoming job will be printed digitally unless it is very long, simple or otherwise has characteristics that make it more appropriate for conventional tools,” says Mahal. “This is the opposite of today’s analog-first mindset. The next big jump in the adoption of digital print in the pressure sensitive label industry will take place with the introduction of the HP Indigo V12. The HP Indigo V12 has been optimized to run at 120 m/m, promoting that shift from analog first to Indigo first.”
Lightning Labels has seen the benefit of HP’s platform first-hand. “We’ve had a long and steady relationship with HP for many years across our business platform,” comments Lightning Labels’ Paulin. “Our operators work closely with HP whenever necessary to ensure our presses are optimized for our lightning-fast customer expectations. HP knows our environment and our market well, and the partnership continues to thrive.”
Digital printing manufacturers are ramping up R&D to continue delivering products that meet the most exacting demands from customers, too. “INX is constantly striving to develop products that surpass customer expectations in terms of adhesion, color gamut and overall performance,” says Sofia Machain, product manager-digital, for INX International Ink Co. “Our team is very aware of all global regulations so we can assure customers that all of our inks are compliant.”
In addition, digital has been quite prevalent in terms of M&A activity. For example, Brook +Whittle (learn more on page 44) has invested in multiple companies for their digital printing expertise. Meanwhile, Resource Label Group has brought considerable digital printing expertise into its family with a host of acquisitions.
“We’re one of the largest HP label printers in the country,” says Mike Apperson, president and CEO of Resource Label Group. “That didn’t come because we had big mega centers. The biggest we had when a location joined the family was three, and now we have one of the largest digital networks for labels in North America.”
According to Mike Degus, SVP of marketing and business development at Resource Label, the company is uniquely positioned to handle all the latest trends in the label and package printing industry, which include the shift toward digital printing.
“We’re perfectly positioned to meet all the mega trends in our industry,” says Degus. “SKU proliferation, sustainability, brand appeal and looking good on-shelf are all things that really play to our asset footprint. The thing that’s probably top of mind right now is security of supply. That’s the advantage of our network, whether that’s redundancy at multiple facilities in order to have backup supply or having sophistication in how you plan the supply chain. Even something as simple as leveraging our other 21 facilities if someone is out of a certain stock, we’re positioned to handle that.”
Lux Global Label, a Lafayette Hill, PA-based label converter, also invested in digital printing by means of an acquisition. The company acquired Levittown, PA-based Labelworx right before the pandemic. Established in 2004, Labelworx is known for its digital printing expertise in prime pressure sensitive, shrink sleeves and flexible packaging and serving a diverse group of consumer brands. Digital capabilities at Labelworx include HP Indigo and Domino. Still led by founder Jack Lang, the facility is known for its excellent quality and
quick turnaround.
For Epson’s Gomez, expect these trends to continue in the future. “The shift in consumer behavior that has been supporting shorter runs – and digital printing along with it – is unlikely to reverse,” he says. “We expect to see more substrate options being offered to consumers to align with trends but at more competitive pricing. We have already seen the growing needs for flexible packaging technologies, and we expect that to continue to be at the forefront of consumer needs
and trends.”
Now is the right time to be in the label printing business, as the industry’s inherent value was on full display during the Covid-19 pandemic. More brands than ever before are requiring labels, especially smaller craft brands or big brands with countless SKUs. The latest printing trends are tailor-made for digital printing.
“Label converters, for the most part, are enjoying a sustained boom in business because long-term trends in consumer behavior accelerated at warp speed during the pandemic,” states Victor Gomez, director of Industrial Labels, Epson America. “Consumers working from home, or hybrid, have turned to e-commerce for many purchases they would have made in person before. These shifts in behavior are well served by digital printing because of its ability to deliver short runs quickly and profitably.”
“During the pandemic, it really has highlighted, more than ever before, the importance of being quick and nimble,” says Bill Myers, marketing manager at Domino. “And digital printing provides that ability, benefiting both converters and brand owners. Converters have been able to produce labels in a very quick and highly productive manner. And brand owners have been able to change their market and brand messaging at a moment’s notice.”
Lightning Labels, a digital label converter based in Denver, CO, USA, relies on the high-quality output, quick response and fast production cycles afforded by the technology. With demand peaking during the pandemic, Lightning Labels’ digital e-commerce platform has allowed customers to print short or long runs for several versions, easily and consistently.
“With container shortages an ongoing issue and concern, we offer low minimums of 50 labels per version, for as many versions as necessary, up to several hundred,” explains Gary Paulin, Lightning Labels’ vice president, sales and client services. “We can quickly accommodate 100,000 quantity runs as necessary. This flexibility is critically necessary during normal times, and even more so now during these uncertain times. We ship most orders in 24 hours, and for most larger runs in 5-7 business days. Consumer demand is also very high at this time and driving the urgency in varied types of orders in virtually all product verticals.”
According to Eli Mahal, head of marketing for HP Indigo Labels and Packaging, one key trend during the past 18 months was the shift of volume from conventional presses to digital assets. The production flexibility and application versatility has spurred converters to invest in digital, in order to produce jobs in the most effective way possible.
“A few notable trends that we’re noticing are the upswing in online business through e-commerce and web-to-print,” says Mahal. “Digital printing is also enabling converters to streamline production by keeping traditional machinery dedicated to the very long runs and diverting more production to digital printing.”
Lightning Labels, which has partnered with HP, expects to see digital converters compete more frequently with long-run flexographic providers while also seeing increased demand and longer runs per version.
“When considering the variety of papers and films we offer, and the multi-version control that is most affordable with our 100% digital platform, in terms of not passing on setup fees or upcharges to our customer base, the prime label digital market will continue to expand and grow exponentially for many years to come,” remarks Paulin. “We see increased competition every year and welcome it. We love what we do and how our customers love working with us, and competition further highlights our expertise and experience over 20 years.”
The e-commerce surge has created an immediate increase for pre-printed barcode labels in the logistics supply chains. “Domino customers have seen a 40-50% increase in demand for variable data labels, and I believe the trend will continue,” states Gary Peterson, senior account manager of Variable Data Printing Solutions at Domino.
Converters are looking to optimize digital’s capabilities, both in terms of customization, individuality and enhancements. Donna Covannon, Xeikon’s director of marketing for North America, notes several other critical trends. “Converters are adding embellishments and tactile elements to their labels,” she says. “And variable information, be it for uniqueness or as added security features for anti-counterfeiting and traceability, are also rising in prevalence. Improvements are also seen with color management features to ensure the right color is produced the first time and then every time afterwards.”
Travis Pollard, vice president and general manager of ASL Print FX, says, “Every label that we print is its own custom project. It can require foil stamping or embossing or variable data or sequential numbers, and we have the tools to do that with our MPS EF Symjet ‘powered by Domino’ hybrid press.”
Each iteration of press technology is improving upon its predecessor with a host of new functions and capabilities. “In general terms, each year sees faster and higher resolution technologies incorporated into the available digital printers,” notes Jay Larsen, general manager/director of R&D - Digital Hardware for INX International Ink Co. “These incremental improvements are important. However, changes to workflow, integrated finishing and variable data, and variable finishing (cut, varnish and more variables per label) are true leaps in capabilities and productivity for those customers who adopt them.”
There are numerous options from reputable manufacturers, and these presses and printers can be found at all price points, with a variety of options for speed, print quality, web widths, embellishment and color gamut. When selecting a technology, be it digital or flexo, there are several factors to keep in mind.
“Digital presses are already producing sellable product in the 160 fpm range,” explains Gomez. “What is the incremental benefit to the converter of even more speed to rival their existing – often already fully depreciated – flexo presses? What is more important to the business owner isn’t burst speed but throughput. And that entails a host of other production issues that don’t usually make it to marketing pieces such as uptime, maintenance routines, and ease of use. If the mechanism for higher linear speed entails adding more complexity to the system – more printheads, for example – the overall benefit is actually much smaller. Something similar applies to resolution. Does a race to higher dpi result in better looking labels? Does a higher dpi matter if it gets lost in the viewing distance of the typical consumer when picking up a product from a shelf?”
One of digital’s greatest attributes is its speed to market. For example, HP has developed The Digital Label Factory, a full, end-to-end ecosystem that gives label converters the agility to thrive in today’s fluctuating markets. HP has designed a blueprint for customers to move from “next-week” to “next-day” delivery, with less labor required and higher Overall Equipment Efficiency (OEE).
Manufacturers have responded to this demand by further enhancing their digital portfolios. HP has unveiled a range that includes the HP Indigo 6K and 8K digital press for narrow web labels, the HP Indigo 25K for mid-web flexible packaging and labels, and the HP Indigo 35K for folding cartons. The other key areas are enabled through a combination of hardware, PrintOS solutions, the new DFE, and new inks.
Epson, meanwhile, has teamed with several important partners to add inline finishing and inspection solutions for its SurePress L-6534VW UV digital label press. This allows converters to choose the production solution that works best – finishing inline or off-line – as their job types and run lengths require.
The rising adoption rate of digital printing will not slow down, either. In fact, Xeikon diversified its digital business in anticipation of future printing trends. Xeikon offers its Cheetah 2.0 dry toner technology, as well as Panther 2.0 UV inkjet technology. The presses are also equipped with the latest automated features. The company offers a wide range of color and workflow services, too, highlighted by its X-800 Digital Front End (DFE), which unifies every facet of Xeikon’s portfolio.
“Earlier this year, we introduced two new models: the CX30 and the CX50 entry level dry toner presses,” says Covannon. “It’s important to note that with each cloud-connected solution, operators can monitor print manufacturing from anywhere on the shop floor by viewing the interfaces/dashboards – 24/7 on a smartphone or any other device.”
That drive for versatility led Dantex to launch its latest product: the PicoColour 254HD digital press. With the addition of PicoColour 254HD, the Pico range now covers five different UV inkjet digital presses: the popular PicoColour 210 Classic, PicoColour 254HD, PicoJet 254, PicoJet 330i (164 fpm, 50 m/m) and the flagship PicoJet 330S high speed model, operating at 250 fpm (75 m/m). All PicoJet and PicoColour 254HD digital presses offer a 2.5 pl dot size and resolution at 1200 x 1200 dpi.
“Our new PicoColour 254HD is the perfect addition to our growing range. With the market readily accepting inkjet as its future, we have listened to our customers and increased versatility across the portfolio of presses available,” says Ben Danon, CEO Dantex Group. “As an established player in the digital press global marketplace, Dantex continues to address the different levels of demand while maintaining the highest quality standards.”
There are options for converters who want to add digital to their arsenal without incurring the costs associated with a brand-new production press. Colordyne, for example, offers its retrofit technology at a fraction of the price.
“Converters are coming to Colordyne because they are looking for an alternative to purchasing a standalone press,” explains Katelyn Bohr, director of marketing at Colordyne. “Many do not have space on their floor without removing a current asset, so we go in and add digital print capabilities to a flexo press already in their facility. Plus, this allows them to maintain the flexibility of running flexo, digital or hybrid on the same piece of equipment based on the jobs they need to run that day.”
New installations
The Covid-19 pandemic did not stop label converters from investing in new digital printing technology. Hub Labels Inc., a Maryland-based label converter, recently installed an HP Indigo 6K digital press. The digital asset will give Hub Labels increased short-run capabilities across a variety of industries, including food, beverage, and health and beauty, to name a few.
For Thomas Dahbura, president and owner of Hub Labels, the HP Indigo 6K digital press will allow the converter to meet a wider range of customer demands. “Over the last two years, label demand has continued to go through the roof,” he says. “Even with all the challenges facing our industry, the economy continues to be strong. Consumers are buying. In the last year, we’ve seen the greatest growth from our small to medium-sized customers.
“By adding the HP Indigo press to our lineup, we are adding more than 10% capacity to our facility,” says Dahbura. “That’s huge for us and our customers. It helps us balance our workload across our presses, offer shorter lead times, and be more flexible with how we fulfill orders. In addition, the print quality is stunning and the right fit for Hub.”
After installing a Domino N610i digital UV inkjet press, Abbott Label recently returned to the digital specialist for a K600i dual bar digital UV inkjet printer to aid with VDP. “Covid hit not too long after that and now everybody needs labels,” says John Abbott, president of Abbott Labels. “From the QR codes to the consecutive bar codes – and that’s where the Domino K600i came in.”
Mammoth Labels & Packaging, located in Colombus, OH, had been farming out its digital printing work prior to the investment in a Domino N610i digital UV inkjet press. The press, which was installed right at the outset of the pandemic, helped Mammoth grow its digital sales 93% in 2020.
“Our flexo customers were looking to shorten their runs and add SKUs,” says Stuart Reeve, president and CEO of Mammoth. “So, in order to satisfy those customers, we took the work and farmed it out to another digital supplier. The choice to bring digital in-house became very simple for us. With the addition of the Domino, our prime label business grew exponentially, specializing in the wine, beer, and candle industries. The Domino has really given us the flexibility to be able to service those customers.”
That success has given Mammoth currency with its current customers, as well as the confidence to approach new prospects. Curt Powell, business development manager at Mammoth, explains, “I think the thing that the Domino has done for us from a sales perspective is it has really given us confidence. So, when we go in and meet with a new client, we have the confidence to say, ‘Yes, we can do that.’”
Chris Merlick, founder and CEO of Label Solutions, made a similar decision to invest in digital, as his company had also been farming out its digital work. Label Solutions entered the digital printing arena by selecting the Durst RSC-E UV inkjet label press.
“When we first started our digital journey and doing our due diligence, we looked at a number of manufacturers,” explains Merlick. “We sent files to all those partners, looked at samples and subsequently had quite a few meetings with them, and it really came down to Durst and one other manufacturer. Through our testing, Durst really rose to the top. We felt that with the 1200 dpi technology and 2 picoliter ink, we’re able to put down a real differentiator in terms of quality. Given that we’re selling ourselves as a premium provider of labels, that was a big part of it. The 1200 dpi technology and the number of Pantone colors we’re able to match with the expanded gamut ink really drove us to Durst.
“The Durst is a Ferrari in a sea of Chevrolets,” he adds. “As a premium label shop, there’s just something exotic about the Durst technology. It sets us apart from a lot of North American label converters, and we’re always looking for differentiators in this business.
Meanwhile, Nova Label, which is based in Maryland, recently installed Colordyne’s 3800 Series UV – Retrofit on a Mark Andy flexo press. In addition to improved durability on its labels, the technology will allow Nova Label to target markets it previously could not such as craft beer. The retrofit features 4-color process and white, but it’s expandable to seven colors in the future if needed.
“The durability of the UV inks and using standard materials was a big advantage, so I think the future looks really bright for that unit and its technology,” states Alan Rich, president of Nova Label. “For what we need to do, Colordyne made the most sense. They’re a good company, and Taylor Buckthorpe has been great. They’ve answered all our questions, and the technicians know the machinery inside and out.”
Colordyne completely redesigned the print engine for the 3800 Series UV – Retrofit based on customer feedback. The chassis, IDMs and software were all engineered to deliver reliability, ease of use and quality to its customers like Nova Label.
“Reliability was a huge element that our customers were looking for,” says Colordyne’s Bohr. “With supply chain disruptions and a lot of uncertainty in 2020, they needed a digital printer they could depend on. Working with our partners, we were able to deliver a retrofittable print engine that met this expectation.”
Screen Americas also just announced a customer’s expansion into label printing with the Truepress Jet L350UV. A traditional offset printer with a primary focus on folding cartons, Pacer Print and Packaging of Chatsworth, CA, shifted 80% of its label business in-house with the new inkjet press. A regular supplier of labels for the cannabis and CBD industries, the printer soon found itself expanding into the wine, liquor and candle industries during the pandemic. Peter Varady, the company’s founder and president, chose to invest in the Truepress Jet L350UV to meet the demand for additional labels.
A first-time Screen customer, Varady was sold on the reliability, durability and stability of the machine. He was also impressed with the customer service he received and the Trust Network Service program. “The Truepress Jet is a real workhorse, and there is an actual team behind the press,” says Varady, who found the transition to digital printing rather seamless.
Stouse, a wholesale print provider, has diversified its business with multiple digital technologies. In the past two years alone, the company’s digital printing investments have included six presses, most recently two HP Indigo 6K roll-to-roll label machines installed in February 2021 to meet increased demand for food, beverage, and consumer products. In order to fully service its customers, the team also purchased a Xeikon 3500 high-definition, 4-color digital folding carton press and launched a paperboard folding carton line with more than 30 market-driven designs.
In Europe, Nord Technique Etiquetage (NTE), a family-owned company based near Lille, with 35 years of experience in label manufacturing, has become the first company in France to install a Bobst digital label press, the Mouvent LB702-UV. It is the second investment in a Bobst machine for the company after it purchased a Bobst M4 inline flexo press in 2016. The investment in digital printing is in response to an increased demand for shorter-to-medium length runs.
Now, according to Thibault Duponchel, general manager at NTE, the company is “perfectly placed” to take on whatever combination of jobs come their way. “Since owning the Mouvent LB702-UV, I’m proud to say I now have a fully optimized production floor by being able to offer the very best technology for all print jobs,” he says. “We’re using flexo for the very long runs and the Mouvent digital press for the rest. It’s clear that with an ultra-quick and productive machine like this, digital is not only for short runs anymore. It’s the perfect tool for short to medium runs, and I am now shifting all jobs of several thousand linear meters to digital.”
Pandemic-proof
The challenges associated with the global pandemic magnified the inherent value of digital printing. Brands needed labels and they needed them quickly. Digital printing presses were able to help meet demand for shorter runs with quick turnaround times. These capabilities led to an influx of digital investments throughout the pandemic, notably from the aforementioned Hub Labels and Nova Label. There were a multitude of other label converters that turned to digital during the uncertainty of Covid-19, too.
“During the pandemic, demand for labels for essential products showed a pattern of strong growth during each wave of infection, followed by de-stocking and re-stocking based on the change in infection rates,” explains Xeikon’s Covannon. “This meant printers and converters needed to be on-the-ready to deliver quickly. For instance, when complementary industries, such as distilleries, turned their operations into making hand sanitizers, they needed labels quickly and affordably. In some cases, they also needed to maintain their brand integrity in these adjacent product label designs. Digital printing enables the short runs and fast turnaround times, especially if there are required design changes.”
“The pandemic has caused a change in several supply chains, with consumers shopping more online than ever before for products and delivery services,” says Marco Zanella, global business development director - Inkjet, for INX International Ink Co. “This has created an increased demand for printing solutions that are more versatile, easily adaptable to variable conditions, and suitable for smaller and diversified demand. Digital printing is made to meet these requirements above others, and we have seen an acceleration of the development and rollout of solutions for printing and decorating items for a large variety of applications.”
For Lightning Labels, the all-digital label converter had contingency plans in place to accommodate the rise in customer demand. This goes hand-in-hand with the flexibility that digital printing offers.
“While it has been challenging to keep pace with demand, we have tooled for it, added skilled staff where needed, and improved our online order portal,” states Lightning Labels’ Paulin. “Additionally, we have ensured consistent inventory levels for the wide variety of papers and films we offer to meet the longer run needs while we’ve seen our competitors struggle to do the same. We continue to innovate and adapt quickly to current market conditions and customer demand.”
According to Colordyne’s Bohr, the pandemic accelerated many of the trends taking place prior to quarantine. “One of these trends includes the adoption and use of digital printing equipment,” she comments. “We all experienced uncertainty and supply chain challenges, which highlighted the efficiency, flexibility, and on-demand benefits that digital printing provides.”
The workforce challenge was also on full display during the pandemic, as many converters and suppliers struggled to attract and keep employees. The inability to hire and retain skilled workers further lends itself to digital’s best attributes such as automation.
“One of the things that easily gets overlooked that digital printing technology has done for the industry is help with workforce development, especially for converters who are trying to attract the next generation of workers to their business,” says Domino’s Myers.
“The printing industry was having trouble replacing retiring pressmen even before the pandemic,” notes Epson’s Gomez. “While younger workers don’t want to spend years in apprenticeships learning how to run a flexo press, digital presses are much more familiar to them, making training easier and shorter. In addition, the automated features of a digital press, like Epson’s SurePress, means a single operator can run multiple presses at the same time. Converters appreciate being able to add print capacity during business spikes like we saw last year and not have to worry about headcount.”
Xeikon has announced version 2.0 of its Panther UV inkjet technology with the launch of two new label presses: the Xeikon PX3300 and Xeikon PX2200.
As the company’s wide portfolio evolves in line with advances in technology, the new presses, which are replacing the existing Xeikon PX3000 and Xeikon PX2000, feature advancement in two areas – applications and building blocks – to digitalize print manufacturing. The new presses are now commercially available in Europe and North America.
Filip Weymans, vice president of marketing, states, “We are defining a pathway to full digitization of print production and manufacturing. Responsiveness has become key for any business and can only be achieved effectively by digitalizing all print manufacturing processes and not just printing. The foundation for a digitalized environment lies with collecting data in a digital manner. The data volume, captured in real time, creates the information that is required by label converters to make fact-based decisions. Another aspect is the interfacing connections in production between machines and operators, helping to transfer job information between the different production processes or drawing the attention of operators when it is really required. The cloud-connectivity, machine-machine and man-machine interfaces of our UV inkjet presses will enable label printers to take operational excellence to the highest levels. They offer great potential to maximize OEE, increase sustainability and make an operation robust for any future challenge.”
The new Panther 2.0 Series also offers new opportunities for label printers to expand their applications portfolio. Xeikon’s new substrate handles technology features a new splice table, web detection capability and cooled roller at the curing section. This makes it possible to print high-quality labels on a wider choice of substrates, including clear-on-clear facestock, which requires a high-quality opaque white to make the design stand out.
Both presses can be configured with a fifth print station for white ink and can print on a wide range of self-adhesive media, in addition to clear-on-clear, including coated paper, vinyl, PP, PE, PET, and metalized.
The Xeikon PX2200 and PX3300 presses leverage the advantages of dedicated PantherCure UV inks, which meet the demands from brand owners for high-gloss, durable labels with high scuff resistance. The Panther DuraCure UV technology produces high-gloss effects and stands out across the widest color gamut while delivering enhanced long-term durability for multiple applications such as industrial, chemical and household labels, as well as high-end labels for the premium beer, spirit, beverage, and health and beauty market sectors, the company says.
Driven by the Xeikon X-800 digital front end (DFE), the new Panther UV inkjet presses offer consistent print quality in combination with excellent productivity. The cloud connectivity is achieved through the X-800, providing access to both machine data and job data such as ink consumption, printing time and so on. The latest generation of Xeikon’s X-800 enables custom applications on the Panther series such as haptic printing. This tactile layer of white delivers the sought-after embellishing effect inline with full color printing for designing labels with enhanced tactility and luxury feel. The technology also features variabilization, starting from black and white and going to color numbering and to the most complex full color variable data application through Xeikon’s new Vari-One option.
The Xeikon PX30000 is available with six (CMYKOV) or eight (CMYKOV+WW) print stations. It will now be accompanied by the Xeikon PX2200, 220mm wide, available with four or five print stations, and the Xeikon PX3300, 330mm, available in four and five print stations or 5C-high capacity. With high-performance levels and low-energy consumption, Xeikon’s Panther Series of presses are now equipped with cloud connection and next-generation HMI. This helps operators monitor the workflow to maximize productivity by avoiding downtime and bottlenecks and make changes on the fly while maintaining full color control.
Weymans concludes, “Xeikon’s UV inkjet presses can address any request from label converters. This can mean replacing an older UV flexo press to be more effective, being cost competitive within the high-end to medium-run label market, expanding the digital application space of existing liquid toner businesses, or providing entry-level investments that allow any printing company to embark into the digital label space. By being part of Xeikon’s broader label portfolio (press, consumables, workflow, converting, embellishing, services), converters can over time expand their investment in width and color, or expand their workflow capabilities with ERP or MIS systems. With over 30 years of experience in digital innovation, Xeikon has a deeper understanding that enables them to offer not only the latest innovations and technologies but also a full suite of support services.”
A digital future
While flexography still accounts for the majority of printed labels, anyone perusing this magazine can attest that the number of digital press installations is skyrocketing.
“Moving forward, we expect to see the continued adoption of digital, but in a way that complements the converter’s existing flexo production,” says Colordyne’s Bohr. “Flexo printing isn’t going away any time soon, but converters are looking at how to add digital print into their business. Having options on how to add digital capabilities, from standalone systems to retrofits, gives label converters the ability to choose which method is best for their business.”
More and more brands will recognize the value that digital printing presents, especially on crowded shelves. This will lend itself to even more digitally-printed projects in the future. “Brand owners are realizing that in order to connect with consumers – to gain and maintain consumer mindshare – they need to differentiate their products on the store shelves and create brand differentiation,” says Domino’s Myers. “And one of the key ways to do that is through labels and packaging. That fits right into the wheelhouse of digital printing. Being able to easily provide variable data, personalization, quickly print shorter runs with more SKUs, etc. And the converters who have digital printing will win that business. Those who do not will get left behind. So, digital printing will continue to grow exponentially in importance, and it already has.”
Hybrid printing will also play a significant role in digital’s adoption in the future, especially as many major manufacturers of both digital and flexographic equipment have teamed up to offer robust solutions to the industry. According to Dave Medlar, vice president of Digital Business Unit, Mark Andy, whether it be strictly digital or hybrid, the technology truly represents the future of label converting.
“When Mark Andy first got into digital, especially with my background in engineering, there was such a desire in the market for a digital product,” says Medlar. “We felt like we had to transform the business over time to digital. Eventually, even if it’s 30 years from now, some 90% of the presses in these label converting plants will have some sort of digital capability.”
The benefit of inline finishing will satisfy many converters’ digital needs over time. Currently, many standalone digital production presses require off-line finishing units.
Digital printing is not just a talking point at Mark Andy, either. To better serve this growing market, Mark Andy has added nine individuals to the company over the past year to support the continued development of its Digital Business Unit in the US and Canada.
With well over 250 digital hybrid placements in the region, significant year-over-year sales increase, and the recent expansion of its digital hybrid portfolio with the introduction of Digital Series iQ to the Digital Series family of products, the company has invested to ensure even more successful results in the future.
“Mark Andy is seeing tremendous interest in digital printing,” notes Medlar. “Nearly all businesses that we have talked to in the label and packaging market have seriously looked at and/or have already acquired some form of digital printing machinery over the last several years. Our customers are looking for digital hybrid printing machines that are able to offer the best quality print, are highly productive and easy to operate. Based on all the feedback we get from customers and prospects, we expect continued high interest in digital hybrid printing going forward.”
Even as digital becomes more commonplace, there will still be a place for all technologies, notes Medlar. “Flexo and digital absolutely complement each other, because every label shop has jobs with different run lengths,” he explains. “So, why choose between flexo or digital? The decision-making process comes down to your cost to print or your ROI for that piece of equipment, and one of the key factors is run lengths. Every label shop is going to have long runs with more and more specialization and regionalization of their products. Some of those run lengths, even when producing the same type of label, require the need for shorter runs, and digital helps complement that activity at your business.”
In addition to digital’s flexibility, the technology is also helping promote environmental friendliness in the industry. This will continue to be a pressing topic going forward. “Sustainability is hugely important within the label and packaging industry,” states HP’s Mahal. “All HP Indigo digital presses are designed with the environment in mind. Not only are they manufactured carbon neutral, they also offer reduced production waste and energy efficiency, and support eco-certified materials, including sustainable primers, varnishes and adhesives. HP Indigo is working with its many partners in the ecosystem to deliver solutions that support a circular economy, conducting testing and validation for recyclability and composability.”
HP also envisions a changing mindset toward digital printing. “Our vision for the label industry is a shift to an Indigo-first mindset, which means that an incoming job will be printed digitally unless it is very long, simple or otherwise has characteristics that make it more appropriate for conventional tools,” says Mahal. “This is the opposite of today’s analog-first mindset. The next big jump in the adoption of digital print in the pressure sensitive label industry will take place with the introduction of the HP Indigo V12. The HP Indigo V12 has been optimized to run at 120 m/m, promoting that shift from analog first to Indigo first.”
Lightning Labels has seen the benefit of HP’s platform first-hand. “We’ve had a long and steady relationship with HP for many years across our business platform,” comments Lightning Labels’ Paulin. “Our operators work closely with HP whenever necessary to ensure our presses are optimized for our lightning-fast customer expectations. HP knows our environment and our market well, and the partnership continues to thrive.”
Digital printing manufacturers are ramping up R&D to continue delivering products that meet the most exacting demands from customers, too. “INX is constantly striving to develop products that surpass customer expectations in terms of adhesion, color gamut and overall performance,” says Sofia Machain, product manager-digital, for INX International Ink Co. “Our team is very aware of all global regulations so we can assure customers that all of our inks are compliant.”
In addition, digital has been quite prevalent in terms of M&A activity. For example, Brook +Whittle (learn more on page 44) has invested in multiple companies for their digital printing expertise. Meanwhile, Resource Label Group has brought considerable digital printing expertise into its family with a host of acquisitions.
“We’re one of the largest HP label printers in the country,” says Mike Apperson, president and CEO of Resource Label Group. “That didn’t come because we had big mega centers. The biggest we had when a location joined the family was three, and now we have one of the largest digital networks for labels in North America.”
According to Mike Degus, SVP of marketing and business development at Resource Label, the company is uniquely positioned to handle all the latest trends in the label and package printing industry, which include the shift toward digital printing.
“We’re perfectly positioned to meet all the mega trends in our industry,” says Degus. “SKU proliferation, sustainability, brand appeal and looking good on-shelf are all things that really play to our asset footprint. The thing that’s probably top of mind right now is security of supply. That’s the advantage of our network, whether that’s redundancy at multiple facilities in order to have backup supply or having sophistication in how you plan the supply chain. Even something as simple as leveraging our other 21 facilities if someone is out of a certain stock, we’re positioned to handle that.”
Lux Global Label, a Lafayette Hill, PA-based label converter, also invested in digital printing by means of an acquisition. The company acquired Levittown, PA-based Labelworx right before the pandemic. Established in 2004, Labelworx is known for its digital printing expertise in prime pressure sensitive, shrink sleeves and flexible packaging and serving a diverse group of consumer brands. Digital capabilities at Labelworx include HP Indigo and Domino. Still led by founder Jack Lang, the facility is known for its excellent quality and
quick turnaround.
For Epson’s Gomez, expect these trends to continue in the future. “The shift in consumer behavior that has been supporting shorter runs – and digital printing along with it – is unlikely to reverse,” he says. “We expect to see more substrate options being offered to consumers to align with trends but at more competitive pricing. We have already seen the growing needs for flexible packaging technologies, and we expect that to continue to be at the forefront of consumer needs
and trends.”