LemuGroup, which has seen significant success with its end of line automation, is taking another step in bringing automation to the label and package printing industry. The company is launching the Ultra Compact 3, an affordable end of line automation equipment setup that drives efficiency and productivity when operating with fewer available resources. 

Converters can utilize end of line automation to expand their existing systems into a multi-line feed, central automated system. The Ultra Compact 3 enables small and medium size converters to focus on printing labels, as opposed to the workforce dilemma impacting the manufacturing space. The new system also boasts a 2-year ROI. 

“The Ultra Compact 3 was developed for the broadest spectrum of the label industry and is priced to fit everyone’s budget,” states Andre Beaudoin, director, North American sales and marketing, LemuGroup. “Label converters big and small have the identical workforce issues of being able to find and retain people. The staffing issue affects converters globally – big, medium, and small. Whether it’s boxing roll labels or sheeted product, the Ultra Compact 3 benefits anyone looking to improve their efficiency and profitability.”

Automation has emerged as one of the label industry’s biggest trends. This new product launch from LemuGroup will help deliver this technology to more companies, allowing them to drive efficiency and productivity in their label manufacturing capabilities.

“Automation is here to stay and has now become the most needed piece of equipment in the pressroom today,” says Beaudoin. “As our need for trade skilled labor has diminished, the need for end of line automation that allows for complete roll to sealed and palletized box has taken over. End of line automation has now become an accepted competitive edge in label converting.” 

The Ultra Compact 3 is currently running successfully at beta sites in Europe. The launch comes on the heels of an impressive demonstration alongside Martin Automatic and ETI Converting at Labelexpo Americas 2024. Based on the early results, the Ultra Compact 3 is poised for a global rollout.

“Customers are clamoring to get this technology,” says Beaudoin. “The system is affordable and effective, as the beta tests showed. We are now formally rolling this system out to the global market, as it is ready for primetime action. Its simplicity of operation and non-stop production have proven what we intended it to be. Label converters from small to large all share this issue and require a solution. End of Line automation is no longer a luxury, it’s a needed tool to compete in the market to ensure customer satisfaction.”

LemuGroup has also seen significant demand for RFID capabilities – another industry trend – especially as large retailers incorporate the technology into their operations. RFID is playing an increasingly crucial role in supply chain traceability, security systems and inventory logistics management. Its ability to increase control over products has made its implementation a necessity for many companies. Customers are looking for solutions that simplify these challenges, and the answer lies in the application of logistics tags with RFID chips. LemuGroup has developed converting equipment for both narrow web and short-run labels as well as for high-volume production.

Among them is a system designed for the production of white logistics labels with the in-line integration of a module for inserting RFID chips, either dry or wet. LemuGroup’s system enables the continuous production of smart labels in large volumes, guaranteeing 100% quality and an efficient manufacturing flow from roll to pallet.

LemuGroup is the recognized industry leader in the production of high speed converting equipment, capable of single operator efficiency and robotic end of line packaging automation that serves a wide variety of label industry converting needs. These converting processes include roll to sheet, RFID, linerless production, high speed diecutting, high speed turret rewinders, modular converting systems, and roll mapping and label editing inspection systems. All of LemuGroup’s systems are produced to be able to be run inline or as an off-line process for maximum flexibility.

LemuGroup has improved production efficiency with advanced solutions, as well. The company has integrated the Tubescan 100% inspection system into the GTU Turret Rewinders, allowing it to detect printing errors, waste and defects larger than .0005 square inches in real time, and fix them quickly so that complete runs are not discarded. This system performs a complete mapping of the errors and records them on the closing labels of the rolls.

“The labels carry detailed information, including a QR code with the Roll Map of the Tubescan system,” explains Beaudoin. “The integration ensures real-time quality control, reducing waste and optimizing production, especially in demanding sectors such as pharmaceuticals, nutraceuticals, RFID and premium labels.”

The demand for these solutions, alongside an economical, automated setup, comes on the heels of a rousing display at Labelexpo Americas in 2024. LemuGroup, alongside Martin Automatic and ETI Converting, showcased the power of full end of line, robotic packaging automation across their three booths. The goal of the three companies was to showcase state-of-the-art technology while addressing the biggest trends in label printing. The Labelexpo booth display combined the strengths of each of the companies as they bring high added value to the market. LemuGroup, Martin Automatic, and ETI Converting all manufacture equipment that can be flexibly configured, providing turnkey solutions to each specific project’s need.

“Attendees were able to see automated converting capabilities running web over the aisles, displaying what’s possible in label printing shops today despite the issue of a shrinking, non-existent labor pool,” says Beaudoin. “We were displaying our high-speed converting capabilities along with automated finishing, eliminating the need for human interaction. This shows converters how they can produce and ship 30-40% more product every day.”

As part of the booth collaboration, LemuGroup displayed its popular GTU-26 rewinder and the new Ultra Compact Robotic end of line boxing and palletizing system. The GTU-26 system can reach production speeds up to 820 fpm (250 m/m), ensuring a perfect rewind and high production process. But the production line doesn’t end in the rewind unit, as the UltraCompact system allows the production process to be completed fully automatically, without stops in each cycle and without the need for any additional labor at the end of the line. Fully integrated, the unit ensures that the entire solution operates synchronously – from roll to pallet.

“The response to our larger Ultra Compact System at Labelexpo was huge,” adds Beaudoin. “The display unit was, in fact, on its way to its new home in the US directly after the show. The interest level was amazing, as people could actually see the system run. Several orders were taken at the show, and the need for client visits and assessments was through the roof. People now understand that the future is here, and we gave them tangible proof that they too can solve their headcount issues with this system.”
With the Ultra Compact Systems, companies only require one operator to run the entire press line/packaging system, from unwind directly to a closed, addressed, and palletized box. There is no need for two or three additional employees to complete the work.

According to LemuGroup, converters can expect a 30-40% increase in daily throughput of finished product at maximum line speed.

“We guide the customer through their ROI process of headcount reduction, and we also provide run rates to give them an idea of how this will improve their production and overall Lean Manufacturing model,” notes Beaudoin. “LemuGroup is with the customer all through this process and long after the system is installed and running production. Our job is to educate the customer about what they already know. We just show them how to do it better, which goes right to their bottom line. It is a true long-term partnership.”

Automation in software has also become a critical tool for LemuGroup. The company has launched LemuGroup Connect, a comprehensive solution based on three levels of connectivity. The first level, Trouble Shooting, allows operators to diagnose and solve problems directly on the machine. The second level, Remote Technical Support, offers real-time assistance through remote assistance and webcam analysis, resolving 96% of incidents without face-to-face intervention. Finally, the third level, LemuGroup Connect, is a web app that allows us to monitor data in real time, anticipate problems and
optimize production.

“With this solution, we help our customers to guarantee quality, reduce costs and minimize downtime,” concludes Beaudoin.

Visit www.lemugroup.com or contact Andre Beaudoin, abeaudoin@lemugroup.com