Flexographic label printing continues to evolve – mainly, with the use of new technologies like digitalization and automation. Therefore, suppliers are engineering the future of flexo. The process is not nearly as manual as it once was. In fact, the industry has designed flexo to attract the next generation of operators. This generation has grown up with technology, and the presses reflect that reality.

For example, real-time monitoring of production run analytics, such as machine KPI’s and “Machine Recorders” will help suppliers like Omet in predictive production modeling and maintenance.

“The digitalization of our process allows us to collect data utilized by AI algorithms to create an environment of machine learning where AI can be used to mitigate human interactions,” explains Paul Teachout, business development, Omet Americas. “Digitalization creates data driven, predictive modeling of our workflows. As a flexo machine supplier our products must transform the way companies monitor, manage, and interact with their machines, enhancing efficiency, productivity, and technical support on a global scale.”

As Omet notes, a component of attracting the younger generation to label manufacturing is convincing them of the industry’s capabilities. This is not a down and dirty manufacturing process of the past. Conversely, flexo has emerged as a very sophisticated, clean-hand production process utilizing the most advanced technologies in the world.

Evolving process

“We have evolved our process from rubber to photopolymer, gear driven to servo motors and with the advent of AI we now move from automation to autonomation,” says Teachout. “Simply put, we are entering the next industrial age from 4.0 to 5.0 and from disruptive to regenerative. Omet presses are designed with future proof technologies and ease of use in mind. Presses must communicate data within to further improve efficiency as run conditions change. The press cannot remain static and must adapt through digitalized communication of components to reduce the need for operator intervention.  These innovations have been designed with the disruptive technologies that today’s generation has been raised on.”

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Recruitment and retainment

One of the biggest challenges in flexo is attracting and retaining employees. The recruitment process must start in high school, where students are deciding on their future.

“We must support career days and apprenticeship programs, to share our industry and all the opportunities it has to offer,” remarks Teachout. “This needs to be done at the grass roots level. If you are having a workforce challenge in your area, find a way to connect with this demographic and share the opportunities our industry presents, a very sophisticated, intelligent and rewarding career path.”

According to Teachout, Omet customers continue to request platforms that provide ease of use and a short learning curve. Providing operators with simplicity and ease of use, quicker setup features and automated register and print controls are a must.

“We need newer technology with complete connectivity, where all production variables can be managed and preloaded and reducing setup delays and production variables,” states Teachout. “For printers to improve their bottom line and reduce operational costs they must invest in future-ready technologies that can lead to a more autonomous production process. The quick and easy answer for this is to offer relief to the growing workforce challenge.”

A digital complement

Popular thinking might have flexo and digital label printing at odds with each other. But the two technologies actually work in tandem. The goal is to optimize the press run with the right job for the right press.

“Flexo and digital technologies will continue to complement each other for years to come,” states Teachout. “For the short and mid run length opportunities digital hybrid provides a very consistent color gamut with virtually no setup time and a full complement of finishing technologies all on a traditional flexo web transportation platform, all in one pass.”

For example, Omet and Durst have partnered together to deliver a powerful solution in this space. The two technologies have a long relationship to evolve and will continue to complement each other in many ways. 

“Over the years I have seen printers have up to 25-30% of their production be short run work,” explains Teachout. “Printers struggled with quick-turn production on traditional flexo presses, where they needed to push out 12 jobs a day. The digital hybrid solutions of today have helped overcome that challenge. We have seen, over the last decade, that hybrid solutions can overcome that 25% freeing up the traditional flexo presses for longer runs. Now when I enter the most efficient facilities, I see one hybrid and three flexo, or two hybrid and six flexo and so on. I feel the proliferation of the digital space has met the market need of that 25% quick turn work and has stabilized a bit, but the growth trajectory will continue as speed and resolution improves.