As label converters look to differentiate their business, digital printing still emerges as a focal point. With many narrow web businesses already boasting in-house flexographic capabilities, attention has turned to new technology that can meet differing demands. However, digital printing has moved past the short-run capabilities that were a staple of early adopters. In fact, current digital label presses can do far more than their predecessors, even from just a few years ago.

“According to industry reports, the market is projected to reach $36.9 billion by 2030, driven by scalability of inkjet technology and increasing demand for short-run, high-quality labels,” states Dario Urbinati, CEO, Gallus. 

Domino, meanwhile, continues to see significant growth in versioning, SKU proliferation, regional variants, and customization. “A major trend report notes that 72% of label printers produced at least 20% more label versions over the past two years,” explains Bill Myers, marketing manager, Domino. “Shorter runs and just-in-time production are increasingly dominant. The digital label printing market is forecast to grow from about $12.3 billion in 2025 to $20.6 billion by 2035 (CAGR ~5.3%).”

The newest press technology incorporates all of the latest trends in one. Digital presses feature far more automation and are easier to operate than ever before. In many ways, the technology has been adapted for the label industry of the future.

“The latest generation of digital printing equipment reflects a decisive shift toward higher speed, greater automation, and data-driven precision,” explains Noam Zilbershtain, VP and GM, HP Indigo. “Modern presses are designed to minimize downtime and operator input while achieving offset-quality output at scale and driving improvements in waste reduction and cost efficiency. Equally significant is the growing integration of connected workflows and cloud-based analytics, enabling printers to make real-time, data-informed decisions that drive productivity, sustainability, and profitability.”

From an economic standpoint, industry acceptance has also brought with it greater affordability. Numerous press manufacturers offer entry-level digital solutions that allow converters to penetrate this market without breaking the bank – especially given economic uncertainty.

“The Domino N410 offers a compelling entry-level, low-cost solution that delivers many of the benefits of digital printing while addressing the practical needs of converters,” remarks Myers. “This press lowers the barrier for converters who want to adopt digital label printing but may have been held back by cost, space, or complexity. By offering a well-known brand with world-class service and support, converters can feel more confident. Digital label printing is a strategic capability. The evolution means converters can now use digital for a wider variety of jobs, shorter lead times, more personalization, and tighter economics.”

Some of the biggest enhancements in digital labels have come with inkjet printing, too. The shift to 1200 dpi inkjet has served as a boon to converters now investing in digital.

“The step from 600 dpi to true 1200 dpi resolution has allowed inkjet to provide the fine type, gradients, and skin tones that were once not possible with lower resolution heads and could only be produced digitally on slower, more costly toner technologies,” comments Steve Lynn, executive director, North America, Durst. “Digital technologies are now capable of true production speeds that rival flexo and don’t restrict digital to only short run, higher cost work. Over the last 5-10 years, digital label technology has evolved and is now producing short/medium and long work with exceptional quality at competitive costs.”

For inkjet specifically, advancements in drop placement accuracy and ink chemistry have brought digital quality to parity with, or beyond, traditional print, acknowledges Tom Mooney, product manager, Xaar. Digital embellishments are also a significant growth area with textured print, foiling and Braille, all available through the jetting of high viscosity inks and fluids.

“Digital print also enables decentralized production with local or near-line printing close to product filling or packaging locations, reducing logistics, waste, and inventory costs,” says Mooney. “This, combined with seamless integration with MIS/ERP systems and the wider supply chain, enables real-time data, traceability, and variable data printing (VDP) to drive the growth of digital.”

The benefits of digital printing can be seen across multiple markets, as well. “Adoption has expanded across industries, such as food and beverage, healthcare and logistics, as digital printing has become increasingly cost-competitive for short and medium runs,” notes Connie Kuo, product manager, Epson America. “Brands are driving demand for personalized and custom labeling to strengthen consumer engagement, support short-run production, and respond quickly to market or seasonal trends.”

While converters were once skeptical about the benefits of digital, those days are long gone. “Over the past decade, digital label printing has evolved from a niche technology, and Gallus has been at the forefront of that transformation,” says Urbinati. “What began as short-run printing has matured into a highly automated process, delivering premium quality, speed, and flexibility.  This development means Gallus customers can now run digital production at an industrial level with faster ROI and the flexibility to meet rapidly changing brand demands.  

“The technology has evolved dramatically in both speed and reliability, with today’s presses operating at industrial duty cycles once reserved for analog,” adds Zilbershtain. “AI-driven automation and closed-loop quality systems, which use real-time scanning to automatically detect and correct deviations, now ensure color stability and accuracy across extended runs, while extended media gamut has opened new applications in packaging and specialty markets.”

Digital vs. Flexo (or Hybrid?)

There are numerous considerations for which technology to deploy for a specific printing job. Historically, the crossover point has focused on digital vs. flexo. However, the growing prevalence of hybrid printing presses presents another option for label converters. 

“Growth in hybrid technology is delivering the best of both worlds by combining digital inkjet units with flexo or finishing stations,” states Xaar’s Mooney. “Here, products such as the Xaar Versatex Printbar enable brands to incorporate high-opacity colors, intricate textures, and varnish effects, creating tactile, interactive features that elevate the consumer experience and which previously only screen or flexo could deliver.”

For Epson, there is a market for each technology. “Converter interest today is split between the flexibility of standalone digital systems and the versatility of hybrid configurations,” explains Kuo. “While there is growing interest in hybrid among mid-size converters seeking to expand their production options, standalone digital remains the preferred choice for operations that prioritize rapid job changeovers, SKU variability, and efficient short-run workflows.”

According to Durst’s Lynn, standalone digital printing makes the most sense for converters dealing with SKU proliferation and requiring short/mid runs (<10–15,000 feet per version). “If next-day delivery models and frequent material changeovers are core to your business model, digital makes the most sense,” says Lynn. “It’s also ideal when work has limited inline embellishment needs or you prefer flexible, modular finishing off-line.”

Lynn says hybrid is optimal when a large share of work is medium/long run quantities (>15,000 feet) and requires varnish/lamination, or cold foil and diecutting in one pass. “If you run longer, versioned campaigns where consolidating multiple web passes saves hours of WIP and handling, hybrid is ideal,” he notes. “Also, if you have limited material changes and common die patterns but regularly changing graphics.  

“A simple rule of thumb: If most jobs are short, fast-turn, and light on embellishment, go standalone digital,” adds Lynn. “If complexity and inline decoration are frequent – and you value one-pass – go hybrid. Now that 1200 dpi inkjet is becoming a mainstream technology,  many successful plants run both, routing by run-length, complexity, and due date.”

Most leading label suppliers have developed solutions to meet each and every need. For example, Gallus offers both standalone digital and hybrid platforms because converter needs differ.

“The Gallus One, a standalone press, is ideal for converters focused on short runs, fast turnaround, and variable data printing,” says Urbinati. “On the other hand, the Gallus Labelfire, a hybrid system, combines digital printing with flexo and finishing in a single line. This approach suits converters who manage a broad mix of short, medium, and long runs, or who need inline embellishment. Our customers often find that the hybrid approach bridges the gap, providing digital flexibility with conventional efficiency. Because Gallus builds both platforms, we can help converters optimize configurations to best match their production strategy and growth targets.”

Looking Ahead

As more and more label converters continue to explore how digital fits their business, the technology will see increased adoption. Flexibility across formats will remain essential, but success depends on choosing the right press for each job.

In the future, converters should expect digital printing technology to continue advancing in ways that enhance customization, efficiency, and sustainability.

“Digital printing in the future needs to deliver flexibility, speed, quality, cost-effectiveness, finishing capability, sustainability, and connectivity,” says Domino’s Myers. “Converters who invest in these capabilities position themselves for evolving brand demands and market complexity. Converters should be looking ahead and asking for features and capabilities from digital printing equipment and systems that will drive growth, resilience, and competitive advantage. But with that, equally if not more important, is the level of advanced operator training that can be provided, as well as service and support.”

“The growing demand for personalized, regulatory, and region-specific labeling will drive further innovation in customization and  variable data capabilities,” adds Epson’s Kuo. “Greater automation and data integration will enable seamless connectivity with production, MIS and fulfillment systems, creating smarter, more efficient workflows. Sustainability will also play a central role, with continued progress in eco-friendly inks, recyclable media, and waste reduction through on-demand printing.

Great Lakes Label goes digital with Mark Andy, Domino

Great Lakes Label recently became the first installation in North America of the new Mark Andy DSiQ-R “powered by Domino” digital retrofit module. The new Mark Andy DSiQ-R was installed onto an existing 10-color, 13″ Mark Andy Performance Series P5 flexo press. The DSiQ-R is a digital retrofit module, designed and built by Domino, for converters to add digital printing capability onto an existing flexographic press – without adding additional footprint.

Utilizing the Domino N610i digital UV inkjet print engine, the DSiQ-R is a compact retrofittable 3-in-1 flexible hybrid solution, allowing Great Lakes Label to maximize productivity for full hybrid printing, digital-only printing, or flexo-only printing. It is a compact, flexible solution without the need for additional space, delivering excellent print quality and production flexibility while taking advantage of quick turnaround and non-stop production for multiple SKU jobs. This retrofit is available from Mark Andy as the DSiQ-R, and from Domino as the N610i-R. 

Great Lakes Label has built a reputation for providing high-quality label solutions across industries that include food, beverage, household goods, automotive, and horticulture. As customer demands shifted toward shorter runs, increased customization, and faster turnaround times, the need for digital printing became clear.

“We have always been focused on innovation,” says Tony Cook, founder and CEO of Great Lakes Label. “With growing demand for shorter production runs and variable printing, we knew digital was the next logical step. But we wanted to do it in a way that complemented our existing capabilities without compromising efficiency.”

Great Lakes Label explored various digital printing options over the years but was drawn to Domino’s technology for its superior quality, reliability, and ability to seamlessly integrate with its current flexographic operations. The company was particularly interested in a solution that would enhance productivity without requiring a complete overhaul of its press lineup.

“Our relationship with Mark Andy played a key role,” explains Cook. “When we learned that they were collaborating with Domino on a retrofit solution, it was exactly what we had been hoping for—an innovative hybrid approach that would allow us to maximize our existing press investments while adding digital capabilities.”

The collaboration between Great Lakes Label, Domino, and Mark Andy exemplifies the power of industry partnerships. By installing the Domino-powered Mark Andy DSiQ-R onto an existing P5 flexo press, Great Lakes Label can now offer its customers greater flexibility, enhanced print quality, and improved turnaround times while maintaining the embellishment and finishing capabilities of its traditional press setup.

The digital retrofit module delivers vibrant print with CMYK+ W digital UV ink, crisp detail, and enhanced durability. Combined with Mark Andy’s expertise in flexographic printing and finishing, this investment positions Great Lakes Label as a forward-thinking leader in the label industry.

“Domino has been in the inkjet game for years, Mark Andy in flexo for years, and the reputations of both companies for quality and service made them the ideal partners for this transition,” says Cook. “With this new capability, we’re not just keeping up with industry trends – we’re setting them.”

In addition, Domino has identified numerous considerations for entering the digital label printing market. Converters should actively seek press technology that includes workflow automation and integration, the ability to produce shorter runs, higher versioning, and personalization, finishing and embellishment capabilities, and cost competitiveness for medium runs.

Modularity is also key when looking at future investment. “You want equipment that allows incremental investment, upgradeability – print modules, retrofits – so the converter can evolve without complete replacement,” says Myers.

Digital printing will also emerge as a remedy for the workforce challenge impacting the label manufacturing space.

“HP Indigo’s vision is that the future of digital printing will be defined by intelligence, connectivity, and true nonstop digital production,” states Zilbershtain. “Presses are quickly evolving into self-regulating systems capable of using real-time data and AI to anticipate issues, maintain stability, and sustain peak performance with minimal intervention. For converters, the priority will be investing in technology that captures and leverages production data at every stage, enabling smarter decision-making and more efficient resource management.”  

According to Xaar’s Mooney, converters should also look for the further integration of digital print into smart factories with the forthcoming changes in GS1 Sunrise, as QR codes will be part of end-to-end automated workflows. “Ultimately, converters should see digital printing as a cornerstone of their own digital transformation, enabling faster decision-making, more flexible operations, and closer customer relationships,” he remarks.

Product Guide

Given the demand for new digital print solutions, suppliers have ramped up R&D to deliver a wide range of products for the market.

Most recently, Domino launched the N410 digital LED inkjet label press. The new press is designed with a compact footprint and low-cost entry to digital adoption. Plus, the Domino N610i-R digital retrofit module integrates on top of a flexo press and provides a 3-in-1 flexible hybrid solution by utilizing full hybrid printing (digital + flexo), digital-only printing, or flexo-only printing. Additionally, since it sits on top of the converter’s flexo press, it does not take up any floor space. On the workflow side, Domino’s Sunrise DFE (Digital Front End) is AI-enabled, offering a job cost calculator, media/substrate manager, fast RIP, and centralized substrate control.    

Durst has developed the G3 standalone platform and KJet Hybrid platforms for the label market. Both are based on the same 1200 dpi native head technology, same inks, and software. “We have also introduced several new productivity enhancements that reduce operator intervention and ensure the highest uptime with a focus on simplicity, reliability, and performance,” says Durst’s Lynn.

For tabletop digital printing, Epson offers several industrial on-demand color label printers, including the ColorWorks CW-C4000, CW-C6000-series, CW-C6500-series and CW-C8000-series. All of these models deliver full-color, durable output from 1″ up to 8″ wide, serving a range of needs from low volume label printing to high volume batch printing.

“Epson’s ColorWorks label printers feature high-performance PrecisionCore technology and are engineered for reliability, delivering crisp, photo-quality color labels on demand,” says Epson’s Kuo. “ColorWorks printers work easily with well-adopted label printing software, including Loftware NiceLabel and BarTender by Seagull Scientific, to streamline label design and variable data printing. ColorWorks also works with a wide range of media, from gloss paper to synthetic film, broadening application versatility.”

Heidelberg and Gallus have expanded their label printing portfolio significantly, from entry-level digital to high-speed hybrid production. Gallus recently unveiled the Gallus Five, a fully integrated hybrid system that combines digital flexibility and conventional technology.

The Gallus Five is built on the Gallus Labelmaster platform, offering native 1200×1200 dpi resolution, web widths of 340mm and 430mm, and production speeds up to 100 m/m. It is aimed at volume-driven markets in the health and beauty, pharma, food, and household sectors and is designed with the System to Compose concept at its core, meaning modularity, future-proofing, and compatibility with existing product lines. 

Plus, the new Gallus Alpha is a pure digital roll-to-roll platform targeted at converters looking to enter digital printing with lower CapEx and high agility.  It offers 1200×1200 dpi resolution, web width of 340mm, “4-color + white” or “6-color + white” configurations, printing speeds around 65 m/m, and is designed for short runs, versioning, and fast turnarounds.  

HP’s portfolio features intelligence and automation. The company says the HP Indigo V12 is “redefining productivity standards for narrow- web digital printing, delivering proven, uninterrupted performance at industrial scale.” Plus, the newly launched HP Indigo 6K+ builds on the success of the 6K platform. It introduces the SmartControlSystem and advanced AI-driven automation to enhance stability and waste reduction. HP also offers proprietary LEP and LEPx, which together enable faster throughput, exceptional color accuracy, and greater media versatility.

Additionally, the HP Indigo 200K, with its double-width configuration and optional inline slitting, extends these advantages into both labels and flexible packaging, enabling converters to expand capacity and transition seamlessly across formats.  

“These presses are supported by an intelligent ecosystem, including HP PrintOS and HP Nio, designed to turn production data into actionable insights,” says HP’s Zilbershtain. “Together, these innovations reflect HP Indigo’s vision for a sustainable, autonomous manufacturing future, where digital printing delivers greater productivity and value across every application.”  

Coupled with AI-enabled process control and intelligent data systems, HP Indigo presses, such as the HP Indigo V12 and HP Indigo 6K+, are adaptive, predictive, and resilient, designed to run smarter and longer in 24/7 manufacturing environments, too. These next-generation platforms reinforce HP’s role in high-performance digital print for labels and packaging. “The LEPx technology and the HP Indigo V12 were developed to meet the industry’s growing demand for higher-volume digital production,” explains Zilbershtain. “As converters face increasing job variability, with more SKUs and shorter average run lengths of around 3–5 km, the HP Indigo V12 was designed to extend digital printing into medium and long runs, enabling nonstop performance at industrial scale.”

Finally, Xaar has built its Versatex Printbar, a versatile platform for integration on existing analog lines, to enable hybrid flexo/digital printing. Here, converters can specifically add digital capability (white, black, varnish, cold foil) to traditional presses.

Powered by Nitrox printheads, the Versatex can jet fluids with viscosities of up to 1,000 centipoise at ambient temperature (around 100 cP at jetting temperature). The Versatex can achieve builds in excess of 200μm, even for demanding print effects such as varnish and cold foil embellishments, white flood fill, black variable data, and digital personalization.   

“For white inks, the Versatex delivers higher opacity than screen printing, enabling strong coverage and overprinting flexibility,” adds Xaar’s Mooney. “Varnish and tactile effects can be added to premium labels and packaging, providing the creative digital embellishments and shelf-impact brands in wine, spirits, and cosmetics demand.”

As well as visual and tactile effects, the Versatex’s ability to add high-build varnish opens up variable data Braille printing, a feature in demand due to legislative requirements. Xaar’s High Creativity mode also makes it possible to add these various textures and embellishments simultaneously in a single pass, streamlining production while enhancing labels with premium finishes.

Mark Andy Continues to Redefine Digital Label Printing

Mark Andy’s Digital Series HD HighSpeed 1200 is redefining what converters can expect from digital print performance. The HighSpeed 1200 is currently the fastest digital press in the marketplace, running at speeds of up to 480 feet per minute while maintaining resolution above 1200 dpi. Doubling the press speeds of its predecessors, coupled with its advanced variable data printing (VDP) capabilities, the HighSpeed 1200 enables converters to significantly boost productivity without sacrificing print quality or precision.

Designed for flexibility, the HighSpeed 1200 supports both hybrid and roll-to-roll configurations, making it an ideal choice for a wide range of applications. Powered by Mark Andy’s ProWORX Digital Front End (DFE), the press streamlines prepress workflows and ensures precise color management, reducing the time from job setup to final output.

A key differentiator of this press is not only its unmatched speed but also its ability to deliver a shorter return on investment (ROI). Converters can produce more labels per shift, expand their color options with CMYKOV or CMYKOVG configurations, and stay competitive with faster turnaround times. Mark Andy’s unwavering dedication to innovation is driving the Digital Series HD HighSpeed 1200 to lead the digital printing industry into a new era of efficiency and profitability.

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