A trend prediction that seems accurate is that production runs are getting shorter while the number of SKUs is increasing. This means we're producing more labels with dynamic designs that add value. Traditional printing methods like gravure and offset are no longer the best options. New technologies like digital, flexography, letterpress, and combi presses are now available. Which is superior? Is this question even relevant?
During the LMAI Conference held in Jaipur on 20-22 July 2023, machine manufacturers highlighted the USPs of these different processes. In the Part-II of the series, Team PrintWeek/WhatPackaging? explains. Rotary Flexo Printing Machine
Digital printing is the visible change-maker. It has its advantages. It can produce short runs fasters and is ideal for variable printing. And when you notice that a strong player in the offset, packaging and print media ecosystem like TechNova Imaging Systems has collaborated with HP Indigo, you know that digital has a significant role in labels and packaging.
TechNova strives to be a prominent provider of solutions for the complete labels and packaging industry. According to Amit Khurana, the deputy CEO of TechNova, their partnership with HP Indigo for their digital presses focused on labels and packaging is a crucial milestone in delivering state-of-the-art solutions to their clients.
Over the years, TechNova has established partnerships with Asahi Kasei and Toray, allowing the company to provide flexo and letterpress plates. The company is now committed to developing a solid flexo ecosystem with a wide range of products, such as eco-friendly consumables, advanced equipment, and groundbreaking software for pre-press, press, and post-press operations.
"We already have a diverse collection of digital printing materials available in our product lineup, specifically designed to cater to the requirements of our flexo clients. Our goal is to become the primary choice for our esteemed customers, assisting them in their business expansion endeavours through our unwavering dedication to originality, advancement, and eco-friendliness," stated Khurana.
In partnership with HP Indigo, TechNova introduces two revolutionary digital presses to its portfolio, the HP Indigo 6K and HP Indigo 35K.
Advantage digital In his presentation, Umesh Kagade from HP Indigo highlighted the benefits of digital printing technology in achieving shorter changeovers. He said, this technology eliminates the need for time-consuming plate and cylinder setups, enabling label printers to switch jobs quickly. This reduces downtime and increases overall productivity.
Kagade explained that HP's digital presses have interactive features, like variable data printing, which meet the need for personalised packaging and improve brand interaction. "Moreover, as some of these new brands expand and require more prints, the digital setup can easily blend with traditional printing methods, offering a versatile and adaptable option."
During his presentation, he emphasised the importance of recognising the full potential of digital printing, even if personalised printing alone may only sometimes justify the investment in technology. He pointed out successful examples of mass customisation projects from various brands in India that have resulted in significant value generation for both the brands and customers. "It is important to have experienced teams that can collaborate with brand managers of FMCG companies to create awareness about the possibilities offered by digital technology."
According to Ajay Raorane of Domino India, the consumer landscape is changing. "Consumers now have more power and expect personalised and interactive experiences."
At the LMAI Conference 2023, the company focused on why labels and packaging converters should adapt to these changing expectations and stay competitive using digital technology.
"Streamlining changeovers is key," Raorane said, adding, "Our new press comes with the latest features that enable labels and packaging converters to reduce the downtime between print jobs. This is critical in meeting the demand for faster turnaround times and accommodating shorter print runs effectively."
Raorane agreed that the initial investment in digital printing equipment may require a significant upfront cost, but the potential for generating revenue and maximising profitability cannot be overlooked. "With the ability to offer personalised labels and packaging, digital printing caters to the growing demand for unique and tailored products. Label converters must analyse their target markets, customer needs, and competition to determine the potential return on investment for digital printing. By effectively marketing their capabilities and leveraging the benefits of digital printing, label converters can confidently unlock revenue streams and achieve a positive return on investment over time."
David Ellen, global divisional director at Domino Printing Business, gave an overview of Domino presses. The N610i is a popular press with 350 installations worldwide featuring a 600dpi printhead, which can print smaller type fonts, and quickly.
He said adoption levels of digital printing in labels are subdued in India compared to what is happening worldwide. Domino has four installations of the N610i presses. "There is a 15% YoY growth (pre-pandemic) in Europe and North America. Market drivers include short runs, increased SKU counts, promotional marketing and brand protection," he added.
Meanwhile, Priyanka Rathi of Jetsci Global highlighted digital printing as a promising technology with vast potential in the Indian market. She emphasised its flexibility, versatility, and capabilities to transcend the limitations of static prints into dynamic labels.
"Embracing digital technologies will be crucial for brand owners to adapt proactively, personalise offerings, improve sustainability, and ensure product safety and transparency throughout the supply chain. Those who leverage these digital innovations are more likely to thrive in this dynamic and competitive landscape," she said.
Stressing that the global label market is valued at USD 41.75-bn, and is expected to grow at 6%, Manish Gupta of Konica Minolta said that digital can add value to short-run and veritable printing jobs. He said Konica Minolta has sold 1,200 AccurioLabel machines worldwide until March 2023.
He also introduced the new AccurioLabel 400, for which he said the company listened to customers' demands and has incorporated these requirements.
Digital with analogue Digital has its disadvantages as well. First, the cost of investment. Second, it's not suitable for long runs. The solution is to build a bridge between digital and analogue.
At the LMAI Conference 2023, Alexander Uwe, the global product manager for digital labelling solutions at Heidelberg-Gallus, introduced the future of label printing through innovative solutions from Gallus. Uwe showcased a variety of machine, material, and software options that will enable label printers to create labels for any occasion, application, or market.
Gallus has recently launched its new Gallus One with converting options. This solution brings everything inline and features a digital printer with an inline flexo station, a semi-rotary die-cutter that can change a job within one minute and process up to 70-m/min, and vision inspection systems.
While discussing Gallus One and the Labelfire 340, Uwe pointed out that job set-up times are a major issue for label printers, whether conventional or digital presses. "These set-up times are the primary cause of lower overall equipment efficiency (OEE) as they significantly reduce the amount of press time available. Uwe also mentioned retrofitting digital units onto the ECS 340 flexo presses."
Label presses in the new generation are remotely connected, allowing a vast amount of press and process data to be stored in the cloud. This data can then be used to produce analytical reports that highlight the presses' performance. "It is crucial today to assess the productivity and efficiency of the presses, and overall equipment efficiency (OEE) is a key performance indicator for label printers. Unfortunately, the average OEE for most label printers is only 20%, indicating room for improvement. However, one can only solve a problem if they know the exact issue. The MIS report can identify the precise problems and their locations," Uwe said.
Flexo flexing Despite changes in the label printing industry, flexo printing remains a crucial component. However, according to Phil Baldwin of Mark Andy, digital presses are becoming more prevalent, particularly for short-run orders. In contrast, flexo presses are becoming wider.
"With the current market challenges, converters have to become more efficient," he said. "Post-Covid, there has been a surge of linerless blank labels. Almost every parcel and package uses linerless labels. It helps reduce wastage."
On the other hand, Bobst sees narrow- and mid-web flexo as the future. "The idea is to digitise and automatise the process," Dario De Meo of Bobst said.
Speaking on more significant savings and simplicity in flexo, Hrishikesh Kulkarni of Miraclon said that brand expectations and market trends are causing a shift towards using flexography for print packaging. "Selecting the appropriate plate matters, as it is the focal point of flexo presses. The right plate can ensure consistent colour and eliminate the need for guesswork during setup for each print job."
Intermittent offset Don't dismiss offset just yet. When combined with other methods, it can still make a significant impact.
At the conference, Naoko Ogawa, the managing director of Iwasaki, and Ranesh Bajaj, the managing director of Vinsak, introduced the world's first intermittent rotary printing press for flexo called IF-330 Conversation.
Ogawa said troublesome ink adjustment is unnecessary since anilox rollers are used. "The plate cylinder can be easily removed and replaced without specialised tools, and job changes can be made quickly," he added. The machine is equipped with standard guideless and single servo shaft-less functions, ensuring high-quality printing with high register accuracy. Various optional units, such as flexo units, rotary die-cut units, laminate units, cold foil units, and flexo-type glue surface and back printing units, can also be added.
Meanwhile, S Kumar Multi Products highlighted the Zonten label presses. A combi press with offset + flexo + gravure, the machine has all three technologies for flexible packaging, IML, shrink sleeves, lamitubes, and of course, labels.
S Kumar Multi Products’ Manish, Aarjav and Tania Hansoti discussed converters' three common challenges: What tech to invest in? How does one cater to short- to medium-run jobs? And how does one provide embellishments in short-run jobs?
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