The perfect storm is often present for label converters. Customers want high-quality labels faster than ever before – at a valued price. Meanwhile, converters are struggling to staff their shops, as employees are retiring or not showing up in the first place. Thankfully, suppliers have been hard at work engineering a remedy to this problem. The solution comes in the form of automation. 

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Suppliers have designed equipment that will allow label printers to do more with less. “Automation has vastly transformed the label industry, offering essential relief for manufacturers facing modern production challenges,” states James Brennan, ABG Connect product manager, A B Graphic International. “As the sector deals with ongoing staff shortages, increased demand for shorter production runs, and mounting pressure to cut waste and energy use, automation has become a revolutionary force. It simplifies complex processes, lessens dependence on highly skilled operators, and improves consistency and accuracy across the workflow.”

“Automation has become essential for converters looking to stay competitive in a rapidly evolving marketplace,” says Joe Settani, director of sales, All Printing Resources (APR). “It not only increases speed and efficiency but also enhances quality, flexibility, and sustainability.”

According to Settani, automation drives success in numerous ways. The newest technologies provide faster changeovers, reduced downtime, and inline finishing and converting – which streamlines production. Meanwhile, accuracy and consistency are boosted, as repeatable results and tighter process control reduces errors and improves output. Customization is another key factor. Scalable and cost-effective automation allows converters to offer short runs and unique designs with competitive advantages. Automation impacts sustainability, as well. Less waste, improved energy efficiency, and faster turnaround times support just-in-time inventory management and reduces environmental impact.  

The demand is there, too. Industry leaders have partnered to bring automation in full force to label and package printing. At Labelexpo Europe 2025, Martin Automatic, ETI Converting, LemuGroup, and Lundberg Tech collaborated on a live production line. The setup served as an encore to their presentation last year in Chicago. The linking booths highlighted cutting-edge, non-stop web-automation, along with coating and laminating. Label converting machinery and automated label matrix waste handling equipment were strong highlights of the exhibition. The focus: Giving converters choices in best-in-class performance in one joint entity. Each partner contributed to their area of expertise.

“Our strategy has always been to lead with original designs and provocative but well-managed goals to deliver results that surpass expectations or even the imagination of the industry,” states Gavin Rittmeyer, VP of sales and marketing, Martin Automatic. “Together, Martin, ETI, LemuGroup, and Lundberg Tech were demonstrating – in real time and in the most difficult of circumstances – what no one else has dared, or dreamed of doing: creating labelstock and converting it live at a European trade show.”

Each participating company contributed its own area of expertise. From Martin’s unwinders, to ETI’s coating, lamination and diecutting, Lundberg Tech’s automated matrix handling and, finally, the LemuGroup GTU Glue turret rewinder and UltraCompact, where the roll is converted, packed, and palletized automatically.

“Running a real production line in such a demanding environment at a trade show is a challenge but also an opportunity to demonstrate the level of integration, automation, and reliability we are capable of delivering,” remarks Iñaki Larrea, CEO, LemuGroup.

Numerous suppliers emphasized automation at Labelexpo Europe, too. Cartes showcased its enhanced digital embellishment system as one of its many highlights, with automation serving as a booth staple. The Cartes Laser featured a setup that added a variety of solutions aimed at processing automation. These features included automatic job changeovers by barcode reading, automatic slitting positioning and turret rewinding systems. Cartes has optimized this combination of automation and digital finishing, the company stated.

Meanwhile, HP has elevated its newest press lines with the inclusion of automation. The new HP Indigo 6K+ digital press, which made its global debut at the event in Barcelona, Spain, features a SmartControlSystem that is delivering on HP’s vision for non-stop digital printing with new levels of automation, robustness, and versatility. Designed to meet any market need, it supports the widest media range, expansive color gamut, and the industry’s broadest portfolio of special inks, enabling converters to confidently take on any job. The new SmartControlSystem enhances uptime and reliability with advanced hardware and software that drive accurate scaling, diagnostics, and serviceability.

“HP Indigo is leading the rapidly evolving labels and packaging industry with non-stop digital printing, intelligent automation, and AI-powered solutions,” states Noam Zilbershtain, VP and GM, HP Indigo. “Our wide portfolio of presses, including the HP Indigo V12, HP Indigo 6K+, and HP Indigo 200K, is designed to meet various printing needs and empower customers to handle any demand at any scale.”

The results are in for ABG, too. Over a two-year development period, ABG collaborated closely with a customer to design and deliver a fully integrated system, comprised of a dual flexo Digicon Series 3 press with an inline Vectra turret rewinder. The entire setup was powered by ABG Connect. “The result was a remarkable 74% increase in efficiency within the customer’s finishing department when running identical jobs before and after installation,” explains Brennan. “This project not only met the customer’s needs but also laid the groundwork for future automation capabilities across our product range.”

For LemuGroup, the company’s high-speed converting capabilities – along with automated finishing – eliminate the need for human interaction. This allows converters to produce and ship 30-40% more product every day.

There is still plenty of room for education, though. “These solutions are becoming easier to incorporate, but the difficulty varies depending on scale,” notes Settani. “Some solutions are relatively simple, such as workflow automation, inline inspection tools, cloud-based integration, and digital label presses. Others, such as fully automated storage and material handling systems, can be much more complex and may require integration in phases.”

A digital future

In many cases, the concept of going digital inherently incorporates automation into a label printing facility. While flexographic presses have become digitized and automated, digital presses have been optimized to simplify the printing process.

“We have met many label converters looking for new technology to advance production efficiency with a desire to automate as much of the print process as possible,” remarks Steve Lynn, director of Labels and Packaging, Durst. “There has been a lot of interest in new digital technologies that advance automation and help reduce staffing challenges that are being seen industry-wide. Converters of all sizes have the same question: ‘How do we reduce lead times, automate as much of the process from file receipt to shipping labels, reduce waste and reduce labor in every step of production?’ The future of the industry will be shaped by some of the new digital technologies that offer solutions to these needs that were seen at Labelexpo.”

Artificial intelligence (AI) and automation will often occur in tandem, especially as converters look to streamline operations. While the implementation of AI is still in its infancy, it will grow along with automated capabilities.

“As with most industries, AI will continue to impact the way businesses operate,” says Settani. “Regarding its future in automation tools, it is rapidly evolving. Basic tools for predictive maintenance, such as press performance, anilox wear, etc., are already in place. However, I envision ‘self-optimizing’ and predictive analytics that will be used to anticipate failure points in future runs, decreasing turnaround times and waste.”

Of course, software plays a key role in the digital printing process, as well. From prepress to printing, automation is now a hallmark of every step of production. 

“We are seeing our software automation make file preparation, color management, variable data, and workflow –  from file receipt to print – more efficient,” says Lynn. “On-press, in hybrid format, we see major advancements in automation with print, embellishment, diecutting, and finishing – all inline. In roll-to-roll format, we see technologies like Hawk AI automate operator functions to reduce job setup time, reduce waste, and maintain print quality at the highest levels with minimal
operator intervention.”

Durst’s Hawk AI technology uses camera vision systems, with the goal of automating print quality. The Durst Hawk AI is not only an inspection system, it goes one step further as it is correcting print mistakes, such as missing nozzles, inline and in real time, without any setup needed and without any
operator intervention.

For ABG, ABG Connect plays a significant role. ABG Connect is an advanced workflow integration platform that links directly with a customer’s MIS (Management Information System). “ABG Connect allows for complete job automation,” says Brennan. “Machines can set themselves up automatically, retrieving job files, adjusting parameters, and even performing quality checks without operator involvement. This level of integration and autonomy is unmatched in the industry, showcasing our leadership in intelligent, connected label finishing.”

For Cartes, digital advancement has come in the form of finishing. “Printers recognize Cartes for our ability to combine digital finishing with patented laser technology and modular platforms. These are the pillars that allow our customers to differentiate in the marketplace while optimizing operational efficiency,” says Virgilio Micale, global sales manager, Cartes.

In LemuGroup’s case, LemuGroup Connect has been developed as a comprehensive solution based on three levels of connectivity. 

The first level, troubleshooting, 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 LemuGroup to monitor data in real time, anticipate problems, and optimize production.

In the future, the size of the converter may very well drive early adoption. Hence, numerous suppliers are looking toward economical automation. 

“Converters’ interest is generally strong, but investment varies with company size, customer demands, and ROI parameters,” explains APR’s Settani. “Large converters are increasingly likely to invest with specific budgets to move to more efficient solutions, especially when these solutions directly impact labor costs or open new revenue streams.  Although interested in these automated solutions, small to medium-sized converters show more caution due to up-front cost and lack of expertise.”

Economical automation

As with many new technologies, price is frequently a prohibitive factor. However, suppliers have worked diligently to enable more converters than ever before to possess the latest automated equipment. 

For example, LemuGroup recently unveiled the Ultra Compact 3. This affordable end-of-line automation equipment setup drives efficiency and productivity when operating with fewer available resources. The Ultra Compact 3, which boasts a 2-year ROI, enables small and medium size converters to take advantage of economical automation, a necessity for so many grappling with workforce challenges. 

“The Ultra Compact 3 was developed for the broadest spectrum of the label industry and is priced to fit everyone’s budget,” explains 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.”

Not only have manufacturers made this technology affordable, they have designed it with simplicity in mind. “Automated machinery makes label production more accessible to operators with less technical experience, lowering the barrier to entry while maintaining high-quality output,” notes ABG’s Brennan. “With automation, tasks that previously required manual effort, such as slitting, rewinding, diecutting, and embellishment, can now be carried out more quickly, accurately and with less waste. The result is a more responsive and agile industry, capable of adapting to changing customer demands and market trends.”

APR has partnered with numerous suppliers to facilitate the growth of automation in the label and package printing space. For example, the company offers a full range of automation solutions designed to optimize pressrooms, including Dantex digital presses with inline finishing (lamination, diecutting, etc.). 

In addition, the TWEN TAC laser anilox cleaner with MicroDynamics Veritas integration has been selected for automated cleaning and measurement. The CAMIS SleeveMaster offers precise sleeve application, while APR also strives for inline color management and inspection systems. 

Automated cylinder, sleeve, and flexo plate storage solutions enhance converters’ operations, as do roll handling systems. Workflow automation tools and cloud-based integration will be critical in the future, too.

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Automating Supply Chain Stress Out of the Pressroom

Automating Supply Chain Stress Out of the PressroomIn today’s competitive label and packaging market, converters are embracing automation to protect uptime, reduce costs, and free up their teams to focus on production. Yet one area often overlooked in automation strategies is supply chain management. Pressrooms still lose valuable hours to manual tracking, last-minute ordering, and the ripple effects of stockouts.

That’s why APR developed SupplySentry, an RFID-enabled inventory management system designed specifically for flexographic converters. Instead of chasing supplies, SupplySentry ensures they are always at the point of use, automatically restocked, and fully visible to your team through a 24/7 dashboard.

The benefits go beyond avoiding stockouts. By collecting real usage data, SupplySentry delivers analytics that help converters identify trends, manage budgets, and streamline processes. Whether monitoring stickyback tapes, doctor blades, or cleaning supplies, converters gain actionable insights without additional staff time or manual spreadsheets.

Converters using SupplySentry report saving more than 15 hours a week in supply management, freeing up floor space, and shifting staff time back to production. They consistently describe the system as simple, seamless, and stress-free. As one user put it: “It’s incredibly easy to use. There’s no learning curve, 10 minutes, and you’re set. APR makes it so seamless that we never have to worry about running out of anything.”

SupplySentry is not a one-size-fits-all solution – it scales to match each converter’s operation with no hidden fees and no penalties for adding or changing SKUs. APR’s technical team ensures a smooth implementation and provides ongoing support, making it a true extension of the automation strategies converters are already adopting. 

As converters continue to push for leaner, smarter operations, automating supply management is the next step. With SupplySentry, APR helps ensure your pressroom is always stocked, always ready, and always focused on what matters most – production.

Learn more at www.supply-sentry.com.