Greg Hrinya, Editor11.11.24
As label converters explore new ways to grow their business, digital printing is one topic that continues to garner interest. With faster turnaround times, lofty quality expectations, and an explosion of SKUs – along with other notable trends like VDP (variable data printing) – digital printing is the go-to for a rising number of label printers.
This trend is not slowing down, as many experts expect digital press sales to outpace conventional technology in the future. The technology is no longer in its infancy, either. The vast improvements in quality and speed have led to a surge in adoption.
For those considering an investment in new technology, this is not your father’s digital press. “For anyone who invested in digital some time ago and feels they understand digital, please look at the latest technology available and put it to the test,” states Steve Lynn, director of Labels and Packaging, Durst.
“Significant developments to printer and ink technology over the last decade have addressed requirements for higher speeds, improved print resolution, and applications such as shrink sleeves, and regulatory issues,” comments Paul Edwards, VP, Digital Division, INX International Ink Co. “These developments tracked the need for shorter runs, more personalization, and features demanded by customers and brands to differentiate products and create value. Many companies entered the market with digital printing systems, so there has been some level of consolidation as the competition has been fierce. Digital printing continues to grow as the technology matures and the secular trend to shorter runs and digitization continues.”
While quality and ease of use are key considerations, digital printing is more cost efficient than it has been in the past. “We are seeing converters purchasing digital equipment to replace analog equipment when profitable,” notes Mike Pruitt, product manager, SurePress, Epson America. “In addition, profit margins are increasing as digital ink and toner prices drop and there is more competition between label press manufacturers. Overall, the combination of flexibility, cost-efficiency, high-quality results, and the ability to respond quickly to changing demands is driving the adoption of digital printing in the label industry.”
With expertise in both flexo and digital, Mark Andy offers an ideal vantage point of the market’s direction. While flexo still accounts for the greater share of labels printed, digital is making strong progress.
“Every year, we continue to see more customers move into digital for many reasons,” cites Ben Luly, product manager, Mark Andy. “With the shortage of talent and highly qualified flexo printer technicians, digital becomes more attractive to younger, entering talent. From the industry side, shorter run lengths with higher levels of versioning, as well as the need for variable data, all create the demand for digital assets.”
While toner historically made up the vast majority of installations, inkjet has made significant inroads. “Digital printing has been around for a long time in the label industry, but the latest developments have led to a faster adoption of digital technology,” explains Lynn. “Most digital in label has been toner-based presses, which offer prime label quality but are limited on speed and cost. 1200 dpi inkjet has emerged as a digital technology that offers prime label quality at high speeds and low cost, and it is changing how digital is perceived in label production.”
According to Steven Calov, digital product manager, Heidelberg USA, inkjet technology is particularly advantageous for frequent design changes, such as QR codes and personalized promotions, benefiting industries like food, beverage, and pharmaceuticals.
“Investing in inkjet technology allows label producers to meet evolving customer needs and achieve margin and revenue growth that traditional methods may not support,” states Calov. “This shift will drive significant innovation and adoption of inkjet solutions in the coming years.”
As most manufacturers offer numerous press and technology options, working with companies to ensure the right solution is selected is critical. A specific digital press might work better for one converter’s book of business and customer requirements than that of a competitor.
“Converters have different needs based on their customer base and work mix, so we like to discuss specific needs and what the future may hold before deciding with a converter on the best solution from our portfolio,” says Lynn. “Too many times a digital purchase is made based on buying the one solution available from a digital supplier, so we prefer to make sure we are addressing needs and offering the best solution for now and the future of a business.”
“We at Heidelberg start by assessing their current challenges,” adds Calov. “Next, we examine how a new digital solution would integrate with their existing workflow. Recognizing that digital printing requires different skills than flexo, I guide them on necessary training and maintenance for optimal uptime. Finally, selecting a vendor that offers strong support, training, and after-sales service is vital for smooth adoption. Digital presses continue to evolve, so it’s important to select a press that offers scalable options – whether the customer needs to expand capabilities in the future or upgrade the equipment as the technology improves.”
Epson provides a consultative approach that analyzes different aspects of a converter’s business, including print volume, ROI, and workflows, to provide the best recommendation for a digital label press purchase. Epson also provides operational and color management training on installation, including making profiles to ensure the widest number of substrates are available for production, as well as ongoing support.
In the case of Mark Andy, some customers would be better suited for flexo than digital. Meanwhile, those requiring digital could see a benefit from choosing toner vs. inkjet. Therefore, converters would be wise to take advantage of the resources out in the marketplace when choosing a path.
“Our highly experienced sales reps are perfectly suited to help our customers on their journey into digital,” states Luly. “Mark Andy has a complete product portfolio to suit the needs of each customer, from small businesses to large multi-facility converters. Using our powerful business tools, we can review each customer’s book of work, average run lengths, requirements for variable data, decorating, etc. and determine the effective cross-over point, cost to print, profitability, and even ROI, and the equipment that suits their needs best. Because Mark Andy excels in the hybrid space, we can provide a configuration that offers the lowest cost to print of each technology working to its strengths, and provide the best converting needs for our customers.”
Thomas Schweizer shows the benefits of Heidelberg’s Gallus One press.
Digital printing also lends itself to satisfying end user and brand expectations. Consumers are seeking a more sustainable product with which they can engage. According to a study from RRD, shoppers would pay more for a sustainable product. The same “(Un)Packaging Reality Report” said that 66% of respondents are likely to make sustainability-led changes to current packaging in the next two to five years.
“Consumer and brand preferences are evolving, with an increasing demand for a sustainable and agile supply chain,” remarks Noam Zilberstein, vice president and general manager, HP Indigo. “The number of SKUs continues to grow, and digital label printing is enabling converters to meet the needs of brands and consumers while driving profitable business growth.”
Another area requiring insight comes in the form of ink innovation. Marrying the right ink to the right press and application is critical for success in digital label printing. “It’s import to have a deep knowledge, which INX has, of digital printing systems, inkjet chemistry, and label applications for both analog and digital printing,” comments INX’s Edwards. “But there are differences in the way inks need to be chosen for digital printing systems. Final application requirements are consistent and, for all intents and purposes, are very similar. However, knowledge of the printing systems for digital is much more important in terms of recommending the right inks.”
“We can expect improvements in the range of inks available, such as eco-friendly, food-safe, tactile, and metallic, and a broader selection of substrates like flexible packaging, direct-to-container printing, etc., which will further expand the applications for digital printing,” adds Heidelberg’s Calov. “There will be a push toward developing sustainable substrates and inks, enabling digital printing to lead the way in offering fully recyclable or compostable packaging solutions.”
The flexo printing process is far more mature in terms of the printing technology, adds Edwards, whereas in digital there are numerous different print engines utilizing different printheads. “Digital inks not only need to be formulated for a specific printhead but also for the specific printing system in question,” he states. “It is a common mistake to expect an ink formulated for one type of printhead will work in all printers in the same way. We often assist converters in choosing the correct ink for the application printhead and printing system.”
The same insight is required for software, which is vitally important in the world of digital. Converters can often run into challenges when not utilizing the right software – or using their current system inefficiently. That’s where automation comes into play.
“Workflow automation is another key point that continues to evolve,” says Mark Andy’s Luly. “The demand for faster prepress times is pushing higher levels of automation and ease of use. Industry 4.0 is here, along with a strong movement toward sustainable production and automation. The speed of full variable data continues to increase, as well.”
“The rise in automation features, such as automated inkjet nozzle cleaning and verification, have led to reduced operator maintenance tasks, allowing them to focus on other important tasks,” adds Epson’s Pruitt. “Increased reliability has reduced downtime and the need for service technician visits.”
Under the leadership of Senior Vice President Dave Telken since 2019, MAPP has expanded significantly. Its offerings cater not only to Mark Andy press users but also to the broader print industry, supported by exclusive partnerships with top-tier brands like DuPont and tesa. These collaborations allow MAPP to deliver cutting-edge products with best-in-class lead times, such as next-day delivery on critical items. Telken notes that “quick access to consumables can make or break production schedules in today’s fast-paced industry.”
A key factor in MAPP’s continued success is its experienced sales team, known for their deep industry knowledge and commitment to customer service. With a 97–99% on-time delivery rate and strategically located warehouses in the US and Europe, MAPP ensures customers receive what they need, when they need it.
Looking to the future, MAPP continues to grow its product offerings with the launch of the MA Print Products Performance Line, a private-brand range that includes anilox rolls, doctor blades, plate mounters, and washers. Additionally, the company is expanding its presence internationally, particularly in Europe and Latin America, positioning itself as a global leader with a customer-first approach.
While it often needs repeating, flexo and digital are not competitors. Leveraging both technologies can ensure the right job goes to the right press. Or, in some cases, a hybrid press could solve numerous problems for a print shop.
“As a hybrid press manufacturer, we see digital as a complement to flexo in multiple ways,” explains Mark Andy’s Luly. “If your shop has a mix of long run and short run work, each technology will offer the lowest cost to print in its respective strength. Flexo and digital can also work together, with each complementing each other in a hybrid format. The benefit to the converter is the ability to take advantage of the lowest cost to print of each technology working to its strengths.
“Applications such as priming, varnishing, flood coating, cold foiling can all be done in flexo, along with operations such as delam/relam, backside printing, etc.,” adds Luly. “Although ECG digital can obtain a very high percentage of the Pantone range, very specific brand colors are often better printed in flexo, as well. Configuring your press as a hybrid takes advantage of most operations typically needed in label production.”
Run lengths often dictate the decision, as well. “For converters handling both long and short runs, a hybrid solution can effectively combine flexo’s strengths with digital’s flexibility,” remarks Heidelberg’s Calov. “This approach opens new opportunities and allows them to transition into digital without fully committing. After determining if digital or hybrid is best, we conduct a financial analysis to evaluate ROI and budget constraints. A hybrid solution can provide a more cost-effective entry into digital while leveraging existing flexo capabilities.”
Bobst is another company that has capitalized on the trend toward digital, recently launching a new Georgia-based Competence Center to showcase its latest innovations. Bobst’s new facility is dedicated to the promotion of the company’s four pillars: digitalization, automation, connectivity, and sustainability. The goal is to move beyond flexo and digital, focusing on one solution to meet label converters’ needs.
“When we say ‘Simplifying Labels,’ we’re talking about the needs of the label industry,” explains Matteo Cardinotti, head of Narrow/Mid Web, Bobst. “We’re designing machines that are easier to be operated, more consistent due to automation, and another answer to quality control. We see a big driver of hybridization where you’re combing printing and converting, but it’s also automation and robotics. Our goal is to come up with a complete solution, and all of that is covered in the connectivity aspect.”
“One of our mottos is to ‘do more with less’,” adds Emilio Corti, head of sales, Business Unit Sheet-fed, Bobst. “With the machines we have here, you don’t need two machines, you can run your jobs in one pass on one machine – which requires one person. And we all know how hard it is to find people today.”
HP, for example, has launched the HP Indigo V12 digital label press to rival flexo speeds. HP touts the ability to replace three flexographic presses with one V12. “With the HP Indigo V12, we demonstrate how converters can print higher volumes at a lower cost, reducing labor hours, waste and tooling,” explains Zilberstein. “Additionally, with the HP Indigo V12, converters can grow their top line and recognize the value of digital print by delivering jobs that could have previously been printed by a flexo press.”
For Durst, automation is a staple of its newest digital offerings. At Labelexpo Americas, Durst introduced its new range of hybrid presses and a new option for its technology called Hawk AI. “This is a revolutionary new system that performs inspection and correction of print at full speed to ensure output is maintained at the highest quality level with no operator intervention,” notes Durst’s Lynn. “We continue looking for ways to innovate and lead the digital marketplace.”
Epson offers two SurePress digital label press solutions to meet a variety of prime label industry printing needs. The SurePress L-6534VW uses UV ink and the SurePress L-4733AW uses a water-based resin ink, and both are driven by Epson printheads, which meet the most current ink safety standards.
“Epson printheads offer increased dpi and nozzle compensation using sophisticated drop placement to deliver smooth gradations, remarkable color quality, and sharp detail,” states Epson’s Pruitt. “Presses feature fewer operator maintenance tasks and are designed for reduced technician visits.”
Heidelberg has launched its Gallus One platform, which integrates advanced inkjet technology, proprietary inks, workflow software, and predictive monitoring through Heidelberg Prinect. This enhances operational efficiency and reduces downtime. With cloud capabilities, users can remotely set up and monitor performance, standardizing processes across multiple presses. The Gallus One is also designed for easy upgrades, so users can expand their capabilities without needing a completely new system.
“Additionally, we unveiled Gallus MatteJet technology at Labelexpo Americas,” says Calov. “This technology delivers a premium matte finish directly within the digital inkjet process. The glossy finish inherent to digital inkjet technology has been one of the foremost barriers to its widespread adoption across labels and packaging. This advancement removes this barrier, particularly for premium segments like wine and spirits, and eliminates the need for post-processing and reduces complexity. By integrating matte finishing into our digital solutions, Gallus MatteJet opens new market opportunities, enabling converters to enjoy the benefits of digital printing while enhancing profitability.”
Meanwhile, Mark Andy used Labelexpo Americas as an opportunity to unveil its new Digital Series HD HighSpeed 1200 platform. “By increasing speeds up to 480 fpm with no compromises in expanded color gamut and full variable data, we are drastically increasing the crossover point over prior digital machines, in some cases up to 60%,” says Mark Andy’s Ben Luly. “With these speeds, high levels of productivity are obtained, which drastically reduces the ROI of the press.”
Luly anticipates further digital advancements in the future, too. He says, “I envision more growth in the digital shrink sleeve market, along with more customers moving to digital for labels. Higher speeds, greater levels of connectivity, and automation will be in the future for the space. I think that we will also see a stronger trend toward LED-cured products and downgauging of material due to the necessary movement in sustainability.”
At the recently held TLMI Annual Meeting in Orlando, FL, USA, the association announced this year’s Best-in-Class winners of the Printing Excellence Awards on the last night of the event at an Awards Dinner attended by over 400 converter and supplier members.
The TLMI Printing Excellence Awards celebrate the outstanding printing and converting achievements in the North American label and packaging Industry. The awards recognize all print processes, including digital, flexography, gravure, offset, rotary screen, and multi-process, and they are open to all converter members.
Of the nine Best-in-Class category winners announced, Domino customers brought home three of those Best-in-Class Awards. Amherst Label, an Inovar Company; ASL Print FX, an AWT Company; and International Label & Printing notched wins using Domino’s digital label printing technology.
Amherst Label, an Inovar Company, was awarded Best-in-Class in the category “Beverage – Alcoholic” for the label 13 Below Cold IPA – Baxter Brewing Company. The label was produced on one of the converter’s two MPS-Domino hybrid presses. Nye Hornor, president of Amherst Label, accepted the award on stage.
In addition to this Best-in-Class Award, Amherst Label was also a First-Place winner with two other labels: All Times Sparkling Cider – Citizen Cider in the “Beverage – Nonalcoholic” category; and Gusto – Seven Birches Winery in the category “Wine & Spirits – All, including neck label.” In addition, Amherst Label earned Second Place in “Wine & Spirits – All, including neck label” for its label Essential Vermont Hopped Gin – Appalachian Gap Distillery – Switchback Brewing Company.
Paul Teachout (L) presents Mark Turk with a TLMI Label Award.
“The three Domino presses allow us to service our customer with the highest quality product,” states Hornor. “The Domino difference has made an Amherst Label difference. We appreciate the support and partnership we have had for over seven plus years.”
Meanwhile, ASL Print FX, an AWT Company, was awarded Best-in-Class in the category “Industrial & Automotive” for the label East Penn Traveller’s Choice RV Care. The label was produced on its Domino N610i digital UV inkjet label press.
Charlie MacLean, president of ASL Print FX, who accepted the award on stage, says, “This TLMI Best-in-Class award truly reflects ASL’s commitment to excellence. From an equipment standpoint, the precision and reliability of our Domino press played a crucial role in achieving this recognition. We look forward to continuing our partnership and pushing the boundaries of label printing together.”
Finally, International Label & Printing was awarded Best-in-Class in the category “Promotional & Extended Content” for the label Laconic Foods Orange Blossom Honey. This label was produced on International’s Nilpeter-Domino hybrid press.
Mark Turk, president and CEO of International Label & Printing, remarks, “We are very appreciative of TLMI and its judging team for bestowing this award to us. We are also extremely grateful for the support of the entire Domino team in receiving this honor. Special thanks also go out to our team at International Label and to our customer, Laconic Foods. We are very proud and happy.”
In addition, Domino customers Label King and Macaran, a NextGen Label Group Company, were award winners as well, with labels printed on their Domino N610i digital UV inkjet label press.
Label King was awarded First Place in the category of “Household – UTC” for the label Elum Designs Disco Cowgirl Boot; First Place in the category of “Wellness, Pharmaceutical, & Nutraceutical” for the label Grizzly Peak Grateful Dave; First Place in the category of “Beverage – Nonalcoholic” for the label Kavahol Alcohol-Free Kava Spirit; and Second Place in the category “Wellness, Pharmaceutical, & Nutraceutical” for the label Hydropro Chocolate Whey Protein. Macaran, a NextGen Label Group Company, was awarded Second Place in the category of “Food” with its label SAP JACK.
David Ellen, Domino global divisional director – Digital Printing, comments, “It’s wonderful to be part of such an amazing association as TLMI and witness the profound way they are honoring the label industry and the excellent achievements of converters. And in doing so, it’s exciting to celebrate the tremendous success of our customers.
“The partnership between Domino and converters goes far beyond providing technology to meet the everyday need to produce beautiful, durable labels for the brands,” he adds. “It’s a relationship built on trust, commitment, and longevity. Watching our customers grow their business, win awards, and celebrate – I could not be prouder.”
This trend is not slowing down, as many experts expect digital press sales to outpace conventional technology in the future. The technology is no longer in its infancy, either. The vast improvements in quality and speed have led to a surge in adoption.
For those considering an investment in new technology, this is not your father’s digital press. “For anyone who invested in digital some time ago and feels they understand digital, please look at the latest technology available and put it to the test,” states Steve Lynn, director of Labels and Packaging, Durst.
“Significant developments to printer and ink technology over the last decade have addressed requirements for higher speeds, improved print resolution, and applications such as shrink sleeves, and regulatory issues,” comments Paul Edwards, VP, Digital Division, INX International Ink Co. “These developments tracked the need for shorter runs, more personalization, and features demanded by customers and brands to differentiate products and create value. Many companies entered the market with digital printing systems, so there has been some level of consolidation as the competition has been fierce. Digital printing continues to grow as the technology matures and the secular trend to shorter runs and digitization continues.”
While quality and ease of use are key considerations, digital printing is more cost efficient than it has been in the past. “We are seeing converters purchasing digital equipment to replace analog equipment when profitable,” notes Mike Pruitt, product manager, SurePress, Epson America. “In addition, profit margins are increasing as digital ink and toner prices drop and there is more competition between label press manufacturers. Overall, the combination of flexibility, cost-efficiency, high-quality results, and the ability to respond quickly to changing demands is driving the adoption of digital printing in the label industry.”
With expertise in both flexo and digital, Mark Andy offers an ideal vantage point of the market’s direction. While flexo still accounts for the greater share of labels printed, digital is making strong progress.
“Every year, we continue to see more customers move into digital for many reasons,” cites Ben Luly, product manager, Mark Andy. “With the shortage of talent and highly qualified flexo printer technicians, digital becomes more attractive to younger, entering talent. From the industry side, shorter run lengths with higher levels of versioning, as well as the need for variable data, all create the demand for digital assets.”
While toner historically made up the vast majority of installations, inkjet has made significant inroads. “Digital printing has been around for a long time in the label industry, but the latest developments have led to a faster adoption of digital technology,” explains Lynn. “Most digital in label has been toner-based presses, which offer prime label quality but are limited on speed and cost. 1200 dpi inkjet has emerged as a digital technology that offers prime label quality at high speeds and low cost, and it is changing how digital is perceived in label production.”
According to Steven Calov, digital product manager, Heidelberg USA, inkjet technology is particularly advantageous for frequent design changes, such as QR codes and personalized promotions, benefiting industries like food, beverage, and pharmaceuticals.
“Investing in inkjet technology allows label producers to meet evolving customer needs and achieve margin and revenue growth that traditional methods may not support,” states Calov. “This shift will drive significant innovation and adoption of inkjet solutions in the coming years.”
As most manufacturers offer numerous press and technology options, working with companies to ensure the right solution is selected is critical. A specific digital press might work better for one converter’s book of business and customer requirements than that of a competitor.
“Converters have different needs based on their customer base and work mix, so we like to discuss specific needs and what the future may hold before deciding with a converter on the best solution from our portfolio,” says Lynn. “Too many times a digital purchase is made based on buying the one solution available from a digital supplier, so we prefer to make sure we are addressing needs and offering the best solution for now and the future of a business.”
“We at Heidelberg start by assessing their current challenges,” adds Calov. “Next, we examine how a new digital solution would integrate with their existing workflow. Recognizing that digital printing requires different skills than flexo, I guide them on necessary training and maintenance for optimal uptime. Finally, selecting a vendor that offers strong support, training, and after-sales service is vital for smooth adoption. Digital presses continue to evolve, so it’s important to select a press that offers scalable options – whether the customer needs to expand capabilities in the future or upgrade the equipment as the technology improves.”
Epson provides a consultative approach that analyzes different aspects of a converter’s business, including print volume, ROI, and workflows, to provide the best recommendation for a digital label press purchase. Epson also provides operational and color management training on installation, including making profiles to ensure the widest number of substrates are available for production, as well as ongoing support.
In the case of Mark Andy, some customers would be better suited for flexo than digital. Meanwhile, those requiring digital could see a benefit from choosing toner vs. inkjet. Therefore, converters would be wise to take advantage of the resources out in the marketplace when choosing a path.
“Our highly experienced sales reps are perfectly suited to help our customers on their journey into digital,” states Luly. “Mark Andy has a complete product portfolio to suit the needs of each customer, from small businesses to large multi-facility converters. Using our powerful business tools, we can review each customer’s book of work, average run lengths, requirements for variable data, decorating, etc. and determine the effective cross-over point, cost to print, profitability, and even ROI, and the equipment that suits their needs best. Because Mark Andy excels in the hybrid space, we can provide a configuration that offers the lowest cost to print of each technology working to its strengths, and provide the best converting needs for our customers.”
Addressing challenges
Digital label printing solves numerous other industry challenges besides short-run printing and customization. By opting for digital presses, converters can help address the labor shortage – with more industry entrants technology savvy – and promote sustainability. The inherent lack of plates and make-ready time generates less waste, fostering a lower carbon footprint for an industry that is constantly looking to make strides in this area.Thomas Schweizer shows the benefits of Heidelberg’s Gallus One press.
Digital printing also lends itself to satisfying end user and brand expectations. Consumers are seeking a more sustainable product with which they can engage. According to a study from RRD, shoppers would pay more for a sustainable product. The same “(Un)Packaging Reality Report” said that 66% of respondents are likely to make sustainability-led changes to current packaging in the next two to five years.
“Consumer and brand preferences are evolving, with an increasing demand for a sustainable and agile supply chain,” remarks Noam Zilberstein, vice president and general manager, HP Indigo. “The number of SKUs continues to grow, and digital label printing is enabling converters to meet the needs of brands and consumers while driving profitable business growth.”
Another area requiring insight comes in the form of ink innovation. Marrying the right ink to the right press and application is critical for success in digital label printing. “It’s import to have a deep knowledge, which INX has, of digital printing systems, inkjet chemistry, and label applications for both analog and digital printing,” comments INX’s Edwards. “But there are differences in the way inks need to be chosen for digital printing systems. Final application requirements are consistent and, for all intents and purposes, are very similar. However, knowledge of the printing systems for digital is much more important in terms of recommending the right inks.”
“We can expect improvements in the range of inks available, such as eco-friendly, food-safe, tactile, and metallic, and a broader selection of substrates like flexible packaging, direct-to-container printing, etc., which will further expand the applications for digital printing,” adds Heidelberg’s Calov. “There will be a push toward developing sustainable substrates and inks, enabling digital printing to lead the way in offering fully recyclable or compostable packaging solutions.”
The flexo printing process is far more mature in terms of the printing technology, adds Edwards, whereas in digital there are numerous different print engines utilizing different printheads. “Digital inks not only need to be formulated for a specific printhead but also for the specific printing system in question,” he states. “It is a common mistake to expect an ink formulated for one type of printhead will work in all printers in the same way. We often assist converters in choosing the correct ink for the application printhead and printing system.”
The same insight is required for software, which is vitally important in the world of digital. Converters can often run into challenges when not utilizing the right software – or using their current system inefficiently. That’s where automation comes into play.
“Workflow automation is another key point that continues to evolve,” says Mark Andy’s Luly. “The demand for faster prepress times is pushing higher levels of automation and ease of use. Industry 4.0 is here, along with a strong movement toward sustainable production and automation. The speed of full variable data continues to increase, as well.”
“The rise in automation features, such as automated inkjet nozzle cleaning and verification, have led to reduced operator maintenance tasks, allowing them to focus on other important tasks,” adds Epson’s Pruitt. “Increased reliability has reduced downtime and the need for service technician visits.”
Mark Andy Print Products (MAPP) drives efficiency in print production
Mark Andy Print Products (MAPP) is a vital partner for printers and converters globally, with a strong focus on boosting production efficiency through high-quality consumables, auxiliary press equipment, and superior customer service. At Labelexpo Americas, MAPP’s extensive portfolio of products – including tapes, anilox rolls, doctor blades, and plate mounting solutions – was showcased, all designed to help converters optimize their pressroom productivity in an increasingly competitive market.Under the leadership of Senior Vice President Dave Telken since 2019, MAPP has expanded significantly. Its offerings cater not only to Mark Andy press users but also to the broader print industry, supported by exclusive partnerships with top-tier brands like DuPont and tesa. These collaborations allow MAPP to deliver cutting-edge products with best-in-class lead times, such as next-day delivery on critical items. Telken notes that “quick access to consumables can make or break production schedules in today’s fast-paced industry.”
A key factor in MAPP’s continued success is its experienced sales team, known for their deep industry knowledge and commitment to customer service. With a 97–99% on-time delivery rate and strategically located warehouses in the US and Europe, MAPP ensures customers receive what they need, when they need it.
Looking to the future, MAPP continues to grow its product offerings with the launch of the MA Print Products Performance Line, a private-brand range that includes anilox rolls, doctor blades, plate mounters, and washers. Additionally, the company is expanding its presence internationally, particularly in Europe and Latin America, positioning itself as a global leader with a customer-first approach.
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Going hybrid?
With inline printing options now available and many companies joining forces to offer hybrid options, converters would be well advised to explore the newest solutions available on the market.While it often needs repeating, flexo and digital are not competitors. Leveraging both technologies can ensure the right job goes to the right press. Or, in some cases, a hybrid press could solve numerous problems for a print shop.
“As a hybrid press manufacturer, we see digital as a complement to flexo in multiple ways,” explains Mark Andy’s Luly. “If your shop has a mix of long run and short run work, each technology will offer the lowest cost to print in its respective strength. Flexo and digital can also work together, with each complementing each other in a hybrid format. The benefit to the converter is the ability to take advantage of the lowest cost to print of each technology working to its strengths.
“Applications such as priming, varnishing, flood coating, cold foiling can all be done in flexo, along with operations such as delam/relam, backside printing, etc.,” adds Luly. “Although ECG digital can obtain a very high percentage of the Pantone range, very specific brand colors are often better printed in flexo, as well. Configuring your press as a hybrid takes advantage of most operations typically needed in label production.”
Run lengths often dictate the decision, as well. “For converters handling both long and short runs, a hybrid solution can effectively combine flexo’s strengths with digital’s flexibility,” remarks Heidelberg’s Calov. “This approach opens new opportunities and allows them to transition into digital without fully committing. After determining if digital or hybrid is best, we conduct a financial analysis to evaluate ROI and budget constraints. A hybrid solution can provide a more cost-effective entry into digital while leveraging existing flexo capabilities.”
Bobst is another company that has capitalized on the trend toward digital, recently launching a new Georgia-based Competence Center to showcase its latest innovations. Bobst’s new facility is dedicated to the promotion of the company’s four pillars: digitalization, automation, connectivity, and sustainability. The goal is to move beyond flexo and digital, focusing on one solution to meet label converters’ needs.
“When we say ‘Simplifying Labels,’ we’re talking about the needs of the label industry,” explains Matteo Cardinotti, head of Narrow/Mid Web, Bobst. “We’re designing machines that are easier to be operated, more consistent due to automation, and another answer to quality control. We see a big driver of hybridization where you’re combing printing and converting, but it’s also automation and robotics. Our goal is to come up with a complete solution, and all of that is covered in the connectivity aspect.”
“One of our mottos is to ‘do more with less’,” adds Emilio Corti, head of sales, Business Unit Sheet-fed, Bobst. “With the machines we have here, you don’t need two machines, you can run your jobs in one pass on one machine – which requires one person. And we all know how hard it is to find people today.”
Digital evolution
Digital press manufacturers are innovating like never before. While hybrid technology has made its mark, with numerous digital and flexographic equipment manufacturers joining forces to meet market demand, standalone digital presses have seen rapid developments.HP, for example, has launched the HP Indigo V12 digital label press to rival flexo speeds. HP touts the ability to replace three flexographic presses with one V12. “With the HP Indigo V12, we demonstrate how converters can print higher volumes at a lower cost, reducing labor hours, waste and tooling,” explains Zilberstein. “Additionally, with the HP Indigo V12, converters can grow their top line and recognize the value of digital print by delivering jobs that could have previously been printed by a flexo press.”
For Durst, automation is a staple of its newest digital offerings. At Labelexpo Americas, Durst introduced its new range of hybrid presses and a new option for its technology called Hawk AI. “This is a revolutionary new system that performs inspection and correction of print at full speed to ensure output is maintained at the highest quality level with no operator intervention,” notes Durst’s Lynn. “We continue looking for ways to innovate and lead the digital marketplace.”
Epson offers two SurePress digital label press solutions to meet a variety of prime label industry printing needs. The SurePress L-6534VW uses UV ink and the SurePress L-4733AW uses a water-based resin ink, and both are driven by Epson printheads, which meet the most current ink safety standards.
“Epson printheads offer increased dpi and nozzle compensation using sophisticated drop placement to deliver smooth gradations, remarkable color quality, and sharp detail,” states Epson’s Pruitt. “Presses feature fewer operator maintenance tasks and are designed for reduced technician visits.”
Heidelberg has launched its Gallus One platform, which integrates advanced inkjet technology, proprietary inks, workflow software, and predictive monitoring through Heidelberg Prinect. This enhances operational efficiency and reduces downtime. With cloud capabilities, users can remotely set up and monitor performance, standardizing processes across multiple presses. The Gallus One is also designed for easy upgrades, so users can expand their capabilities without needing a completely new system.
“Additionally, we unveiled Gallus MatteJet technology at Labelexpo Americas,” says Calov. “This technology delivers a premium matte finish directly within the digital inkjet process. The glossy finish inherent to digital inkjet technology has been one of the foremost barriers to its widespread adoption across labels and packaging. This advancement removes this barrier, particularly for premium segments like wine and spirits, and eliminates the need for post-processing and reduces complexity. By integrating matte finishing into our digital solutions, Gallus MatteJet opens new market opportunities, enabling converters to enjoy the benefits of digital printing while enhancing profitability.”
Meanwhile, Mark Andy used Labelexpo Americas as an opportunity to unveil its new Digital Series HD HighSpeed 1200 platform. “By increasing speeds up to 480 fpm with no compromises in expanded color gamut and full variable data, we are drastically increasing the crossover point over prior digital machines, in some cases up to 60%,” says Mark Andy’s Ben Luly. “With these speeds, high levels of productivity are obtained, which drastically reduces the ROI of the press.”
Luly anticipates further digital advancements in the future, too. He says, “I envision more growth in the digital shrink sleeve market, along with more customers moving to digital for labels. Higher speeds, greater levels of connectivity, and automation will be in the future for the space. I think that we will also see a stronger trend toward LED-cured products and downgauging of material due to the necessary movement in sustainability.”
At the recently held TLMI Annual Meeting in Orlando, FL, USA, the association announced this year’s Best-in-Class winners of the Printing Excellence Awards on the last night of the event at an Awards Dinner attended by over 400 converter and supplier members.
The TLMI Printing Excellence Awards celebrate the outstanding printing and converting achievements in the North American label and packaging Industry. The awards recognize all print processes, including digital, flexography, gravure, offset, rotary screen, and multi-process, and they are open to all converter members.
Of the nine Best-in-Class category winners announced, Domino customers brought home three of those Best-in-Class Awards. Amherst Label, an Inovar Company; ASL Print FX, an AWT Company; and International Label & Printing notched wins using Domino’s digital label printing technology.
Amherst Label, an Inovar Company, was awarded Best-in-Class in the category “Beverage – Alcoholic” for the label 13 Below Cold IPA – Baxter Brewing Company. The label was produced on one of the converter’s two MPS-Domino hybrid presses. Nye Hornor, president of Amherst Label, accepted the award on stage.
In addition to this Best-in-Class Award, Amherst Label was also a First-Place winner with two other labels: All Times Sparkling Cider – Citizen Cider in the “Beverage – Nonalcoholic” category; and Gusto – Seven Birches Winery in the category “Wine & Spirits – All, including neck label.” In addition, Amherst Label earned Second Place in “Wine & Spirits – All, including neck label” for its label Essential Vermont Hopped Gin – Appalachian Gap Distillery – Switchback Brewing Company.
Paul Teachout (L) presents Mark Turk with a TLMI Label Award.
“The three Domino presses allow us to service our customer with the highest quality product,” states Hornor. “The Domino difference has made an Amherst Label difference. We appreciate the support and partnership we have had for over seven plus years.”
Meanwhile, ASL Print FX, an AWT Company, was awarded Best-in-Class in the category “Industrial & Automotive” for the label East Penn Traveller’s Choice RV Care. The label was produced on its Domino N610i digital UV inkjet label press.
Charlie MacLean, president of ASL Print FX, who accepted the award on stage, says, “This TLMI Best-in-Class award truly reflects ASL’s commitment to excellence. From an equipment standpoint, the precision and reliability of our Domino press played a crucial role in achieving this recognition. We look forward to continuing our partnership and pushing the boundaries of label printing together.”
Finally, International Label & Printing was awarded Best-in-Class in the category “Promotional & Extended Content” for the label Laconic Foods Orange Blossom Honey. This label was produced on International’s Nilpeter-Domino hybrid press.
Mark Turk, president and CEO of International Label & Printing, remarks, “We are very appreciative of TLMI and its judging team for bestowing this award to us. We are also extremely grateful for the support of the entire Domino team in receiving this honor. Special thanks also go out to our team at International Label and to our customer, Laconic Foods. We are very proud and happy.”
In addition, Domino customers Label King and Macaran, a NextGen Label Group Company, were award winners as well, with labels printed on their Domino N610i digital UV inkjet label press.
Label King was awarded First Place in the category of “Household – UTC” for the label Elum Designs Disco Cowgirl Boot; First Place in the category of “Wellness, Pharmaceutical, & Nutraceutical” for the label Grizzly Peak Grateful Dave; First Place in the category of “Beverage – Nonalcoholic” for the label Kavahol Alcohol-Free Kava Spirit; and Second Place in the category “Wellness, Pharmaceutical, & Nutraceutical” for the label Hydropro Chocolate Whey Protein. Macaran, a NextGen Label Group Company, was awarded Second Place in the category of “Food” with its label SAP JACK.
David Ellen, Domino global divisional director – Digital Printing, comments, “It’s wonderful to be part of such an amazing association as TLMI and witness the profound way they are honoring the label industry and the excellent achievements of converters. And in doing so, it’s exciting to celebrate the tremendous success of our customers.
“The partnership between Domino and converters goes far beyond providing technology to meet the everyday need to produce beautiful, durable labels for the brands,” he adds. “It’s a relationship built on trust, commitment, and longevity. Watching our customers grow their business, win awards, and celebrate – I could not be prouder.”
