Greg Hrinya, Editor10.10.23
Automation has emerged as arguably the biggest trend in label printing – and manufacturing – in general. While speed and efficiency, sustainability, and the workforce are also hot topics, automation addresses all three. Technology has allowed label converters to do more with less, at faster speeds, and with fewer errors. Fewer mistakes lead to less waste and, ultimately, more sustainable practices.
Automation runs the gamut in label printing. Printing presses, converting machinery such as winding and splicing equipment, and finishing units have all benefited from this technological revolution. There is not one aspect of our industry that has not evolved in rapid fashion. Flexo presses, specifically, have been designed for the operator of the future.
“We have gone from gear box driven machines to servo driven automation creating new levels of efficiency,” states Paul Teachout, technical marketing and content specialist, Harper Corporation of America. “These new opportunities have allowed us to automate many operational functions on the machine platforms. The ability to collect and store digital data and recover for future production runs has improved our repeatability and created ease for a new generation of operators. But it is no longer enough to say we can collect and store production data, have onboard inspection, and color management. These are all common attributes of the modern flexo press. The next generation of intelligent production platforms is right in front of us, and we must prepare.”
“Just looking at flexo presses and thinking about pre-register systems, re-register systems, automatic print pressure adjustments, inspection cameras, and so on – automation has made its mark,” says Frank Hasselberg, president, Prati USA. “All these technologies are simplifying the process and are helping to lower the skill set required to produce high-quality labels.”
LemuGroup has engineered equipment based on end-of-line automation, where the machinery can run day and night – minimizing the human touch factor. This is ever more critical when converters can’t attract the necessary manpower. Therefore, the right equipment allows converters to be more productive with fewer human interactions.
“The onset of end-of-line automation allows for the machine to run all day and everyday as long as there is one operator to run the system,” explains Andre Beaudoin, director, North American sales and marketing, LemuGroup. “This has replaced the familiar model of needing two to three people, who do not exist in today’s workforce, at the end of the press trying to keep up with what is coming off of the turret rewinder.
“LemuGroup’s GTU turret rewinders can be ready for the next job within 10 minutes, and all information for each job is stored for auto setup the next time that job needs to run,” adds Beaudoin. “Our robotic packaging is also tied into this job storage. The automation literally makes the box, fills the box, seals and then addresses the labels on the box. The box is then placed on a palletizer and filled, where it is taken to an awaiting truck or taken to the warehouse. All of this happens at 820 fpm. The system does not stop unless you do.”
Digital printing presses are inherently automated, as the requirement of a skilled operator is vastly diminished compared to flexo press operators of the past. For example, Epson’s SurePress L-6534VW features nozzle maintenance, which includes checking of nozzle function and helps keep productivity high, total cost of ownership low, and press operation simple.
“Preset functions allow on-button change of substrates without readjustment or calibration,” comments Mike Pruitt, product manager, Epson America. “Many image processes, such as half-toning, are done on-press, eliminating the need for an extra layer of software. The robotic controller allows direct control of printhead and web functions without an extra PC or software layer. Automatic web tension and alignment result in accurate registration and reduced web breaks.”
Epson’s press is virtually automatic, requiring no manual cleaning of the printhead surface. Meanwhile, the L-4733AW is primed for unattended printing. This press boasts the optional SureSpectro AS-4000 inline spectrometer for real-time automated measurements to speed profiling and ensures consistent output for multi-plant networks. According to the company, the L-4733AW delivers accurate spot colors and gradients required for brand-quality color prime labels and packaging.
According to Teachout, digital hybrid presses are the perfect example of automation’s impact on the label and package printing industry. These presses are characterized by open platforms that can combine conventional flexo, digital and third-party integrations of embellishments, laser diecutting and finishing.
“Combining these fully connected intelligent innovations into a single platform will provide the most flexible and efficient production,” he says. “The future is fully digitized, data-driven manufacturing with complete cloud-based connectivity. Well-designed integrated solutions can go from roll to shipping carton in a single pass.”
When looking at Prati’s portfolio of finishing equipment, automation now reigns supreme. Most of the slitting units on Prati machines are equipped with FastCut systems, where the slitting knives are set with robotic fingers.
“The operator just enters the distance between the knives and the number of lanes into the HMI,” explains Hasselberg. “The system sets the top and bottom knives at the right distance to each other by itself, the knife pressure to the bottom knives and to the perfect cut. And it only takes less than one minute to set all slitting knives in the right position.
“Even a highly skilled person will need at least 10-15 minutes to complete the setting of slitting knives,” he adds.
Adaptability is a hallmark of automated equipment, too. These machines can be fully customized for converters’ specific workflows.
“Converters simply need to call us and discuss their requirements and issues,” remarks Beaudoin. “Our system is adaptable to most other already-owned equipment on your floor. In this way you do not need, in most cases, to start out with an entirely new converting or press line or turret rewinder. We can calculate, based on volumes, line speed and various other factors, how much additional productivity the system will provide and an aggressive ROI that has a very fast payback.”
There are several factors to keep in mind when getting started with this process. Converters will need to optimize their workflows to handle automation. “Integrating your label press with the correct application interface and appropriate RIP, scheduling, and cost-estimating software, allows for accurate communication to the press to better streamline the automation process,” explains Pruitt. “The most difficult part in the integration of automated label workflow is the release of the necessary APIs for the press and working further with the multiple service vendors to provide the necessary tools to efficiently run their respective press.”
“Labor is the most critical issue for your businesses going forward,” says St. John. “Labor is a diminishing resource. For a fairly labor-intensive industry, this is a problem we need to start paying attention to.”
The workforce challenge has been growing for some time, although the Covid-19 pandemic exacerbated the problem. Now, management is spending a good portion of their day navigating HR and hiring issues versus the day-to-day tasks that keep a business profitable.
“Unfortunately, we are still experiencing a tremendous lack of manpower in the workplace across the board,” says LemuGroup’s Beaudoin. “Since Covid-19, the workforce issue problem has only gotten worse, not better. Converters still need to get product out the door but are spending a third of their time in HR roles looking for help that they cannot find – and if they do, how do they retain them? Our system eliminates the need for this frustrating and time consumptive drill. We have seen increases in daily output as high as 40% or more and a reduction in staff overhead and all costs associated with that.”
Automation has mitigated some of the damage, as new tasks can be completed without the presence of diminishing labor.
“The beauty of automation is that any human activity that is predictable or repeatable can be automated,” notes Harper’s Teachout. “This has allowed the machine interfaces to be much more friendly and a newer generation workforce to rely more on the science rather than a craft. The workforce issue will continue to be a concern as labor is a diminishing resource. Automation and the growing presence of AR and AI will ease that pain. As a newer workforce raised on disruptive technologies becomes the dominant labor resource, we must rely on intelligent solutions to close the gap between labor challenges and operational objectives.”
“Since the industry is facing tremendous challenges recruiting skilled labor, it becomes increasingly important to automate the process of label production and simplify it,” adds Prati’s Hasselberg. “The more automation, the easier it will be for label printers to deliver a high-quality product with a less skilled labor force.”
Digital printing will continue to see increased adoption for multiple reasons. The technology assists with higher quality and print speeds, especially for short runs, but it is also easier to operate than a flexo press – a key consideration when struggling to find labor. “There will be more jobs run on automated digital as labor is scarce for production on analog,” says Epson’s Pruitt. “We will continue to see that companies from all areas of the market are interested in investing in digital technology, and technology in general, that can help to drive their businesses forward.”
The work can be accomplished quite successfully, too. “Because the SurePress L-6534UV is automated, the throughput is high and the labor input low,” says Pruitt. “The press has printed more than two million square feet per month of sellable products for our customers – not because of pure print speed, but because of consistent and repeatable, non-drifting print quality, reliable operation, ease of use, and top service made possible by automation.”
“The future possibilities are endless,” says Teachout. “As automation evolves into a more intelligent workflow, AI will be more of an influence. As we continue to innovate the digitalization of data, we will develop the ability to overcome complex issues. AI simulates human intelligence and will learn to utilize this data to identify and overcome complex issues in real time. The future is the complete digitalization of data-driven automated platforms utilizing cloud-based connectivity, and will intelligently determine the safest and most cost-effective production solutions. Imagine an intelligent factory with a consciousness to do the right thing. Are we really that far away?”
Hybrid Software and A B Graphic International (ABG) have announced a collaboration to streamline operations and enhance efficiency on the shop floor. The integration between the two companies is centered around three key areas that promise to deliver increased operational enhancements.
The partnership promises to deliver a streamlined setup with automated slitting parameters. Hybrid Software’s automation will seamlessly transmit slitting parameters to the ABG Digicon Series 3 machine through the ABG Connect platform. This integration will effectively eliminate the need for manual setup, reducing human touchpoints and paving the way for increased productivity.
The two companies are also emphasizing enhanced inspection automation. The partnership brings about a more automated process for driving ABG’s proprietary camera inspection technology, fleyeVision. Through a direct link to Hybrid’s CLOUDFLOW software, fleyeVision can retrieve the “golden image” required for inspection, minimizing the potential for errors and optimizing QC.
Efficient laser cutting is also critical. The ABG DigiLase machine will benefit from CLOUDFLOW’s ability to incorporate QR codes representing corresponding dielines for laser cutting. ABG’s technology ensures precise and efficient laser cutting.
ABG’s automated capabilities were on display at Labelexpo Europe.
Matt Burton, ABG sales director, states, “We are very pleased with this new collaboration with Hybrid Software, which marks another significant step toward reducing manual touchpoints in our processes. This is another key component of our ABG Connect package as we push toward automation that will not only add greater efficiencies but also reduce operator error while reducing waste and downtime.”
Bert Van der Perre, associate director of sales at Hybrid Software, adds, “Linking our prepress automation solution to ABG equipment elevates the overall equipment effectiveness for our many mutual customers. This partnership extends the boundaries of our software’s capabilities, showcasing our commitment to pushing the boundaries of innovation.”
Automation runs the gamut in label printing. Printing presses, converting machinery such as winding and splicing equipment, and finishing units have all benefited from this technological revolution. There is not one aspect of our industry that has not evolved in rapid fashion. Flexo presses, specifically, have been designed for the operator of the future.
“We have gone from gear box driven machines to servo driven automation creating new levels of efficiency,” states Paul Teachout, technical marketing and content specialist, Harper Corporation of America. “These new opportunities have allowed us to automate many operational functions on the machine platforms. The ability to collect and store digital data and recover for future production runs has improved our repeatability and created ease for a new generation of operators. But it is no longer enough to say we can collect and store production data, have onboard inspection, and color management. These are all common attributes of the modern flexo press. The next generation of intelligent production platforms is right in front of us, and we must prepare.”
“Just looking at flexo presses and thinking about pre-register systems, re-register systems, automatic print pressure adjustments, inspection cameras, and so on – automation has made its mark,” says Frank Hasselberg, president, Prati USA. “All these technologies are simplifying the process and are helping to lower the skill set required to produce high-quality labels.”
LemuGroup has engineered equipment based on end-of-line automation, where the machinery can run day and night – minimizing the human touch factor. This is ever more critical when converters can’t attract the necessary manpower. Therefore, the right equipment allows converters to be more productive with fewer human interactions.
“The onset of end-of-line automation allows for the machine to run all day and everyday as long as there is one operator to run the system,” explains Andre Beaudoin, director, North American sales and marketing, LemuGroup. “This has replaced the familiar model of needing two to three people, who do not exist in today’s workforce, at the end of the press trying to keep up with what is coming off of the turret rewinder.
“LemuGroup’s GTU turret rewinders can be ready for the next job within 10 minutes, and all information for each job is stored for auto setup the next time that job needs to run,” adds Beaudoin. “Our robotic packaging is also tied into this job storage. The automation literally makes the box, fills the box, seals and then addresses the labels on the box. The box is then placed on a palletizer and filled, where it is taken to an awaiting truck or taken to the warehouse. All of this happens at 820 fpm. The system does not stop unless you do.”
Digital printing presses are inherently automated, as the requirement of a skilled operator is vastly diminished compared to flexo press operators of the past. For example, Epson’s SurePress L-6534VW features nozzle maintenance, which includes checking of nozzle function and helps keep productivity high, total cost of ownership low, and press operation simple.
“Preset functions allow on-button change of substrates without readjustment or calibration,” comments Mike Pruitt, product manager, Epson America. “Many image processes, such as half-toning, are done on-press, eliminating the need for an extra layer of software. The robotic controller allows direct control of printhead and web functions without an extra PC or software layer. Automatic web tension and alignment result in accurate registration and reduced web breaks.”
Epson’s press is virtually automatic, requiring no manual cleaning of the printhead surface. Meanwhile, the L-4733AW is primed for unattended printing. This press boasts the optional SureSpectro AS-4000 inline spectrometer for real-time automated measurements to speed profiling and ensures consistent output for multi-plant networks. According to the company, the L-4733AW delivers accurate spot colors and gradients required for brand-quality color prime labels and packaging.
According to Teachout, digital hybrid presses are the perfect example of automation’s impact on the label and package printing industry. These presses are characterized by open platforms that can combine conventional flexo, digital and third-party integrations of embellishments, laser diecutting and finishing.
“Combining these fully connected intelligent innovations into a single platform will provide the most flexible and efficient production,” he says. “The future is fully digitized, data-driven manufacturing with complete cloud-based connectivity. Well-designed integrated solutions can go from roll to shipping carton in a single pass.”
When looking at Prati’s portfolio of finishing equipment, automation now reigns supreme. Most of the slitting units on Prati machines are equipped with FastCut systems, where the slitting knives are set with robotic fingers.
“The operator just enters the distance between the knives and the number of lanes into the HMI,” explains Hasselberg. “The system sets the top and bottom knives at the right distance to each other by itself, the knife pressure to the bottom knives and to the perfect cut. And it only takes less than one minute to set all slitting knives in the right position.
“Even a highly skilled person will need at least 10-15 minutes to complete the setting of slitting knives,” he adds.
Adaptability is a hallmark of automated equipment, too. These machines can be fully customized for converters’ specific workflows.
“Converters simply need to call us and discuss their requirements and issues,” remarks Beaudoin. “Our system is adaptable to most other already-owned equipment on your floor. In this way you do not need, in most cases, to start out with an entirely new converting or press line or turret rewinder. We can calculate, based on volumes, line speed and various other factors, how much additional productivity the system will provide and an aggressive ROI that has a very fast payback.”
There are several factors to keep in mind when getting started with this process. Converters will need to optimize their workflows to handle automation. “Integrating your label press with the correct application interface and appropriate RIP, scheduling, and cost-estimating software, allows for accurate communication to the press to better streamline the automation process,” explains Pruitt. “The most difficult part in the integration of automated label workflow is the release of the necessary APIs for the press and working further with the multiple service vendors to provide the necessary tools to efficiently run their respective press.”
The remedy for labor shortages
Ask anyone in our industry, and they will say they have a hiring problem. Claudia St. John, president, Affinity HR, noted 26 states have reached a record low unemployment rate this year. However, eight million jobs have gone missing due to the pandemic, either from retirement, death, long covid, mothers choosing not to return to work, among other factors.“Labor is the most critical issue for your businesses going forward,” says St. John. “Labor is a diminishing resource. For a fairly labor-intensive industry, this is a problem we need to start paying attention to.”
The workforce challenge has been growing for some time, although the Covid-19 pandemic exacerbated the problem. Now, management is spending a good portion of their day navigating HR and hiring issues versus the day-to-day tasks that keep a business profitable.
“Unfortunately, we are still experiencing a tremendous lack of manpower in the workplace across the board,” says LemuGroup’s Beaudoin. “Since Covid-19, the workforce issue problem has only gotten worse, not better. Converters still need to get product out the door but are spending a third of their time in HR roles looking for help that they cannot find – and if they do, how do they retain them? Our system eliminates the need for this frustrating and time consumptive drill. We have seen increases in daily output as high as 40% or more and a reduction in staff overhead and all costs associated with that.”
Automation has mitigated some of the damage, as new tasks can be completed without the presence of diminishing labor.
“The beauty of automation is that any human activity that is predictable or repeatable can be automated,” notes Harper’s Teachout. “This has allowed the machine interfaces to be much more friendly and a newer generation workforce to rely more on the science rather than a craft. The workforce issue will continue to be a concern as labor is a diminishing resource. Automation and the growing presence of AR and AI will ease that pain. As a newer workforce raised on disruptive technologies becomes the dominant labor resource, we must rely on intelligent solutions to close the gap between labor challenges and operational objectives.”
“Since the industry is facing tremendous challenges recruiting skilled labor, it becomes increasingly important to automate the process of label production and simplify it,” adds Prati’s Hasselberg. “The more automation, the easier it will be for label printers to deliver a high-quality product with a less skilled labor force.”
Digital printing will continue to see increased adoption for multiple reasons. The technology assists with higher quality and print speeds, especially for short runs, but it is also easier to operate than a flexo press – a key consideration when struggling to find labor. “There will be more jobs run on automated digital as labor is scarce for production on analog,” says Epson’s Pruitt. “We will continue to see that companies from all areas of the market are interested in investing in digital technology, and technology in general, that can help to drive their businesses forward.”
The work can be accomplished quite successfully, too. “Because the SurePress L-6534UV is automated, the throughput is high and the labor input low,” says Pruitt. “The press has printed more than two million square feet per month of sellable products for our customers – not because of pure print speed, but because of consistent and repeatable, non-drifting print quality, reliable operation, ease of use, and top service made possible by automation.”
Glimpse into the future
If converters have not started to explore the automation of their facilities, now is the time. As was the case with digital printing, this trend is quickly becoming a necessity.“The future possibilities are endless,” says Teachout. “As automation evolves into a more intelligent workflow, AI will be more of an influence. As we continue to innovate the digitalization of data, we will develop the ability to overcome complex issues. AI simulates human intelligence and will learn to utilize this data to identify and overcome complex issues in real time. The future is the complete digitalization of data-driven automated platforms utilizing cloud-based connectivity, and will intelligently determine the safest and most cost-effective production solutions. Imagine an intelligent factory with a consciousness to do the right thing. Are we really that far away?”
Hybrid Software and A B Graphic International (ABG) have announced a collaboration to streamline operations and enhance efficiency on the shop floor. The integration between the two companies is centered around three key areas that promise to deliver increased operational enhancements.
The partnership promises to deliver a streamlined setup with automated slitting parameters. Hybrid Software’s automation will seamlessly transmit slitting parameters to the ABG Digicon Series 3 machine through the ABG Connect platform. This integration will effectively eliminate the need for manual setup, reducing human touchpoints and paving the way for increased productivity.
The two companies are also emphasizing enhanced inspection automation. The partnership brings about a more automated process for driving ABG’s proprietary camera inspection technology, fleyeVision. Through a direct link to Hybrid’s CLOUDFLOW software, fleyeVision can retrieve the “golden image” required for inspection, minimizing the potential for errors and optimizing QC.
Efficient laser cutting is also critical. The ABG DigiLase machine will benefit from CLOUDFLOW’s ability to incorporate QR codes representing corresponding dielines for laser cutting. ABG’s technology ensures precise and efficient laser cutting.
ABG’s automated capabilities were on display at Labelexpo Europe.
Matt Burton, ABG sales director, states, “We are very pleased with this new collaboration with Hybrid Software, which marks another significant step toward reducing manual touchpoints in our processes. This is another key component of our ABG Connect package as we push toward automation that will not only add greater efficiencies but also reduce operator error while reducing waste and downtime.”
Bert Van der Perre, associate director of sales at Hybrid Software, adds, “Linking our prepress automation solution to ABG equipment elevates the overall equipment effectiveness for our many mutual customers. This partnership extends the boundaries of our software’s capabilities, showcasing our commitment to pushing the boundaries of innovation.”
