Digital printing has been all the rage in the label and package printing industry of late, but flexographic label printing is still very much the future. In fact, the two technologies can work side by side in accomplishing a wide range of brand owner demands – from a short-run craft beer label to several million labels for a global mass market beer brand. While digital printing makes more sense for some jobs, flexo is still the preferred method for long runs. And converters can optimize their print shops by designating a certain label order for the correct press, ensuring the facility is operating at maximum efficiency.

The digital printing market still only accounts for a small percentage of labels, even with adoption on the rise. For many large label converters, which are technology agnostic, the size and nature of the order will dictate the chosen technology – and, in many cases, it will still be flexo.

“Today’s label market continues to drive to more SKUs, shorter run lengths, increased customization and complex applications, and an increasing range of substrates,” says Dan Maurer, VP of digital product management, Heidelberg USA. “The latest conventional presses, like the Gallus Labelmaster, have been designed from the ground up with these requirements in mind. The latest conventional presses are built around a modular platform that can be configured to the changing needs of the label manufacturer.”

Equipment manufacturers have responded in kind. This is not your father’s flexographic printing technology. Suppliers have engineered the modern flexo press to meet the requirements of the future press operator – complete with automation, clean-hand technology, faster speeds, and a reliance on data, among other factors.

Technology has advanced to a place where flexo, once thought of as an art, has become much more of a science. “Gone are the days of relying on mechanical finesse and a good eye for color to produce the perfect label time and again,” states Jesper Jørgensen, global sales manager, Nilpeter. “Now we are talking state-of-the-art software rather than mechanically controlled presses.”

“It is important to note that the younger generation entering the workforce is used to looking at touchscreens and automation rather than getting their ‘hands dirty’ on manual adjustments,” adds Richard Miedema, global sales director, MPS Systems.

The flexo process has undergone more of a revolution than evolution. Mainly, automation has overhauled the process. According to Ken Brown, product and business development manager, Bobst, color digitalization is revolutionized by oneECG, simplifying the process. Additionally, prepress automation empowers a shift from manual tasks to automation. Operations like artwork preflight, cloud approval cycles, imposition creation, oneECG spot color conversion, and finishing automation are now handled by the system. 

“Profiling has been transformed through guided procedures, too,” says Brown. “Integrating measurement hardware and software allows for automatic measurements and real-time software feedback regarding errors encountered. This provides suggestions based on measured data, streamlining troubleshooting. Flexo platemaking embraces automation for a more efficient photopolymer production process. This not only reduces material waste and production times, but it also ensures traceability and consistent production repeatability.

“Automation extends to prepress stage output prediction. Employing color strategies and print proofs, it allows for accurate output predictions,” adds Brown.

Press innovations have been complemented by advancements in inks, plates, anilox rolls, and so much more. “The need for more environmental sustainability has pushed consumables to find ways to achieve this,” states Alex Bullock, business development manager, Omet Americas. “Ink formulations have evolved, offering more consistency, better adhesion and durability, and faster curing. Plates with computer-to-plate technology have improved printing quality. Laser engraving technology has improved the ink transfer of the anilox, and ceramic and chrome coatings have enhanced durability. Overall, consumables are constantly improving.”

“The design of the printing units around servo-driven direct drives (gearless) for the cylinders and anilox rollers, as well as having all printing units on one axis, allows for the quick exchange of printing elements, whether they be flexo, screen, foil, embossing, diecutting, or even OEM units,” explains Maurer. “The platform being designed around two stations per module allows for customization of the configuration and expansion for the future, including the possible integration of a digital printing unit. With print manufacturing embracing Lean Manufacturing practices to drive job cost efficiency and reduced waste, the presses incorporate quick change printing cylinders, aluminum cylinders on the Labelmaster, automated cylinder washing, quick change unwinders and rewinders, and automated presetting functions that the operator implements though an easy to use HMI touch panel.”

The latest innovations in flexo consumable products addresses the drive for sustainability. For example, LED inks offer low energy consumption and are suitable for food applications when compliance is proven and material compatibility is considered. However, for specific food packaging needs, UV flexo inline printing remains a viable option. 

“Flexo plates and screening have seen significant improvements in quality and efficiency over the past decade,” says Brown. “Software and hardware advancements have led to a higher quality overall output. Notably, the introduction of a new solventless thermal process for plate production has significantly improved the eco-friendliness of this aspect.”

Nilpeter strongly believes that 2023 was a banner year for flexography, and moving forward, the printing process will work together with digital printing – competing in some areas and working harmoniously in others.

“We firmly believe that combining flexographic techniques with digital hybrid technology combined with automated technologies is the way forward, promising exciting advancements in the years to come,” remarks Nilpeter’s Jørgensen. “The two technologies do not only compete, they get one and another to constantly seek improvements. Certainly, they also cooperate and complement each other, allowing for the best of both worlds for the right applications.”

Even with flexography, there is a digital component to the future. “I do see converters relying upon both technologies,” remarks Bullock. “Digital is great for short runs, and Omet partners with Durst for the hybrid platform. Both flexo and digital complement each other and the companies that offer both technologies have a competitive advantage. Omet flexo technology and automation delivers quality comparable to digital, and it is ideal for the runs that are not so convenient due to run length on digital.”

“The concept of inline flexo digitalization has been a long-standing challenge in our industry, dating back to the rise of digital printing a decade ago,” states Brown. “Initially, flexo was seen as an alternative to digital. However, with the introduction of Bobst’s all-in-one concept, the comparison has shifted. Today, both technologies are viewed as complementary elements within a hybrid or all-in-one printing process.”

Even with a future that includes both flexo and digital, converters still have a lot to learn about both technologies. Cross-over points can vary from company to company, for example.

“I think many converters have a digital/flexo technology mix in-house these days,” acknowledges Miedema. “Both technologies have their pros and cons in which they excel and provide the best return. But most of the time it is more complicated than to simply compare both technologies from a cost per print standpoint – other factors come into play.

“Workflow around the press is very important to effectively run the job on the press it is most cost-effective on. When you look, in practice, still a lot of work is run on a digital press that probably should have been run flexo and the other way around, too.”

Automating flexo

Automation has emerged as the latest hallmark of the newest flexographic product launches. Faster speeds, more data, and less make-ready time are all possibilities by automating the flexographic process. The market requested these advancements, and suppliers have responded.

“We’re noticing strong demand from the market for enhanced automation features on our flexo machines, and it’s clear that this is the direction we’re headed in the future,” says Martin Teilberg, global marketing manager, Nilpeter. “We’re continuously adding new layers of automation aimed at reducing setup times and boosting both the efficiency and utilization of each press. Our goal is to ensure that our technology remains at the forefront of the industry, providing our customers with the tools they need to succeed in a competitive landscape.”


MPS has prioritized investing in this realm, as it sees automation as the future of flexo. “We are investing heavily in connectivity and forms of Artificial Intelligence to enhance the operator experience on MPS presses in order to become more efficient, sustainable and to promote best practice standard operating procedures at our customers,” says MPS’ Miedema.

Automation accomplishes numerous goals for label converters. “Automation allows you to increase productivity, reduce downtime and reach your sustainability goals by reducing waste and time,” says Omet’s Bullock. “It also allows you to be more consistent with quality. Omet’s state-of-the-art automation allows the press operator to register any job with a special vision system that works in fully automatic function.”

According to Gallus, the servo-driven module approach, as well as automation controls in other areas like web tension, registration and drying, provide for substrate media profiles to be set up once and stored for repeat jobs, reducing make-ready time, reducing waste, and improving job consistency within runs and on repeat jobs. “The overall operation of the press becomes easier and the automation is driven through user friendly touch screen HMI’s that guide the operator,” says Heidelberg’s Maurer. “Cylinder washups are done automatically, as well.”

Omet has developed the capability of connecting to the press remotely for troubleshooting. Meanwhile, Sefra is a digital platform offered by Omet that empowers growth through machine supervision, Lean analytics, dialog with operators, advanced maintenance and advanced sustainability. 

While automation is a key focus for all suppliers, there are a number of factors to keep in mind. “Automation is key, but it is not just about motorizing certain adjustments such as pressure setting and register setting,” explains Miedema. “It is about intelligent use of the automation and using it to assist the operator with even the most challenging setups and production situations. Our presses can automate register positions and pressure settings independent of what material is being run, or adjusted automatically as run speeds change. We call this Dynamic Print Control.”

Navigating the labor crisis

While the manufacturing industry as a whole is facing workforce challenges, nowhere is this more evident than in flexo printing. Many press operators are reaching retirement age, and the next-generation workforce is not adequately replacing them. Therefore, automation has become a staple in many print facilities.

“I travel a lot and visit many customers in the USA, and there is one common theme that I hear – a lack of skillful operators,” notes Omet’s Bullock. “Automation is key to achieve an ROI and to keep up with the demands of the market. The skills of the press operator are no longer a determining factor in daily operations.”

Manufacturers are doing their part to enhance the equipment to a place where employees of the future, many of whom have grown up in a digital world, will be enticed to enter this space. “Undoubtedly, the industry is facing a labor shortage challenge, a situation that both we and others in the field are, and should be, keenly aware of,” comments Nilpeter’s Teilberg. “That said, the significant advancements in flexo technology are playing a crucial role in addressing some of these issues. We take this seriously and are in continuous dialog with our customers about how we can support each other in finding solutions. This collaborative approach is essential as we navigate these challenges together, seeking innovative ways to overcome workforce shortages while pushing the boundaries of what’s possible in flexography.”

The incoming group of operators today also have different expectations from their work with the equipment and the production environment, says Heidelberg’s Maurer. “The counter to this is that the industry and market keep pushing for increased productivity, the highest quality, and more complex applications. Gallus focuses on making our equipment as easy to operate as possible and minimizing touches on the equipment. The touchscreen HMI is designed to be intuitive and engaging with the operator. The job parameters and media profiles are entered by the operator, some with tutorials or wizards to assist the process and then stored, reducing make-ready time on repeat jobs. Even videos are being incorporated into the software, as well as make-ready wizards to improve the ramp up time of a press operator’s expertise.

“The presses are also designed for a more diverse workforce with the presses requiring less physical effort to operate,” adds Maurer.

No matter how automated the process becomes, flexography is still inherently complex. Therefore, simplifying the process for operators is paramount – especially when factoring in the workforce challenges facing so many companies today.


“An important factor attracting even less-skilled operators is the user-friendly interface of modern presses like the Master M6,” states Bobst’s Brown. “Despite the complex technology behind them, these presses present a user-friendly experience. Additionally, the high level of automation allows operators to focus on pre-job preparation, resolving complex printing issues, and maintaining quality control. The Master M6 exemplifies this, enabling operators to switch between jobs in seconds with a single button press.”

The solutions go beyond equipment advancements, too. The industry as a whole needs to better sell the opportunities that currently exist in label printing, specifically on the flexo side.

“As a manufacturer of printing machinery, we also bear a significant responsibility, and we’re deeply committed to securing the future workforce,” says Teilberg. “To this end, we’re actively involved in organizing events and offering educational programs for students, recent graduates, and individuals who are new to the industry. These initiatives are designed not only to spark interest in flexography and printing technologies, but also to provide hands-on learning that prepares the next generation for the challenges and opportunities that lie ahead. By investing in the education and training of potential talent, we aim to foster a skilled and knowledgeable workforce that can carry the industry forward, ensuring its growth and sustainability for years to come.”

What’s new?

Bobst boasts an “All-in-One” concept that allows for a complementary relationship between press technologies, but under specific conditions. For example, a high-speed digital press could be combined with an automated flexo press. “The key factor here is maintaining complete control over the production floor, not just individual presses,” explains Bobst’s Brown. “Converters rely on their entire workflow, and both flexo and digital technologies have their strengths.”

According to Brown, Bobst’s inline flexo presses have been praised for their automation. “We continuously strive to enhance process perfection for application versatility,” he says. “Our focus aligns with the growing demands from brand owners for sustainable solutions, including the AD LinrSave project (linerless applications) and oneBARRIER technologies.”

PRINTING United returns to Las Vegas in 2024

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Heidelberg-Gallus launched its newest digital platform, the Gallus One, in 2023. This platform is based on the conventional Labelmaster design, which provides flexibility for different platforms of the future. The Gallus One brings a new level of production uptime for a digital label press – above 95%, with several new design innovations for improving the life of the inkjet heads, as well as the output quality consistency, notes Maurer.

“The Labelmaster and RCS have continued to be very successful for our customers with many new orders for customized configurations coming in,” he adds. “Their fully servo-driven modular platforms provide tremendous production with fast make-ready in complex applications while providing a robust press that is viable for a very long time and even upgradeable.”

MPS’ newest product launches center around data and connectivity. Most recently, MPS released its VirtualCoach, which is a new product of the MPS connectivity and performance service offering to enhance the quality and efficiency of printing press performance. It is a real-time innovative operating tool that works within MPSConnect and is available on all new MPS presses. 

“As a personalized, data-driven AI instructional and guidance application, VirtualCoach is based on intelligent algorithms that give the operator awareness on the quality and efficiency of all the activities they are performing on the press,” says Miedema. “Basically, we try to steer operator behavior toward best practices and standard operating procedures so that the asset itself can work at its highest utilization.

“Fact is, that you can only do this when your press is completely automated,” Miedema adds. “We take all signals coming from each button, sensor, motor or drive and immediately translate it into valuable information used to predict the operator’s next step. Similar to a GPS you might have in your car, it simply steers the operator into the right direction, in the quickest way possible.”

Nilpeter has made numerous strides to optimize its equipment for the next-generation workforce. In 2023, Nilpeter unveiled the upgraded version of the company’s flexo flagship, the FA-Line, which now places an even greater emphasis on automation and, with its new software, better meets customer needs. Additionally, for the first time ever, Nilpeter introduced the FA-26, designed for value-added short-run flexible packaging and labels.

“We’re observing a trend toward broader applications, moving into flexible packaging, and this machine perfectly supports that shift. It also features our latest camera solution, Vision, fully integrated into the Nilpeter NPL system, offering rapid and exceptionally precise registration,” says Nilpeter’s Jorgensen. “The vision system captures registration on each unit cross and length directional in real time, with a 4K HD camera. The impressive speed of data handling ensures instant adjustment and keeps tight dot2dot register on all materials, following acceleration/deceleration. The vision system also includes the conventional Nilpeter register systems as a part of the package and does allow an unrevealed stack of undisclosed opportunities to follow.”

Nilpeter has also announced the latest addition to the FB-Line, the FB-14/-17, a flexo press that positions itself between the company’s existing FB and FA Lines, with a focus on automation. Nilpeter is touting its Digital Shadow, as well, which, among other features, captures all batch data and OEE data combined with CO2 data to support sustainability and optimize processes.

Omet has engineered different platforms that are custom-made to the needs of the customer. “We offer from 13″ wide up to 33″ wide presses, and we specialize in pressure sensitive, unsupported material, and light carton for the label and flexible packaging industries,” says Bullock. “We can print and convert stock from 12 microns up to 24pt tag. Some of our newest options are the semi-rotary die station, Jetbar, eBeam, screen printing and RFID inline, to mention a few.”

Omet has also developed solutions in the mid-web space, where it offers platforms up to 33″ wide for the shorter and mid runs of flexible packaging. Omet notes its 26″ X7 and its VaryFlex up to 33″ are proven platforms for the flexible packaging and folding carton industries.

GT Etiketten & Labels adds more Mark Andy flexo capacity

Gert Talen (the GT in the company name) began life in the graphic arts industry as a flexo printer back in 1988. Through various endeavors in the intervening years, he has built a reputation for being a great solver of print problems and is often referred to as “Gert the Label.” Today, with son, Luke, and daughter, Anna, he owns and manages GT Etiketten & Labels based at Schoonebeek on the Dutch/German border, which affords him easy access to the packaging markets of Western Europe. Flexography has played a key role in the company’s success.

GT Etiketten & Labels, which opened just prior to the Covid-19 pandemic in 2020, is based in an 1,800 square meter factory unit that was fully refurbished prior to the first label being produced in September of that year. With a staff of 15, company sales will exceed €6.2m in 2023. The converter is showing a healthy growth rate of 20% year on year, working a flexi-shift pattern five days a week. Beginning life with two used presses, which Talen subsequently sold for a profit, production really got into gear with the installation of the first Mark Andy press in 2022.


That Mark Andy is an Evolution Series E3, 8-color flexo line with 430mm (17″) web width. It was followed by two Mark Andy Evolution Series E5 presses, installed in August 2023. Both are 8-color with a 430mm web width and all three have GEW LED/UV capability and are fitted with ABG Vectra turret rewinders. Additional features include Teknek web cleaning and a Vetaphone corona treater, delam/relam, turnbars, cold foil, automatic and pre-register capability, diecutting, a touchscreen interface for a BST Powerscope vision system, and a servo driven cantilevered lower rewind with 40″ (1,016mm) capacity and taper tension.

Speaking for Mark Andy, Maarten van Bergeijk of local agent Packtion, comments, “These are highly capable production tools with a wide substrate range and 230 m/m (750 fpm) running speed. They will offer GT Etiketten the scope to develop the business in a variety of ways with innovative products for new market sectors if they choose. The company’s production floor is now an excellent showcase for Mark Andy flexo technology in the Benelux region, and we are grateful to the management team for this valued cooperation.”

Around 80% of work at GT is produced for the food sector with logistics and pharmaceuticals making up the balance. Currently, the company is printing predominantly on top-coated paper substrates, but Talen sees a swing toward filmic with PP and PE for their recyclability properties. “We are currently trialing water-wash adhesives that will save around 80% of recycling costs over the way the labels are currently produced,” he explains. “This is good for presentation as more of the product can be seen through the packaging and is especially appreciated by the meat and bakery sectors.”

Flexo printed labels can be cold foiled, laminated or varnished with a choice of matte, gloss, or UV finish, with a peel/reseal facility to double the image area. All are produced to BRC standards and supplied with migration reports and data sheets compliant with packaging for the food industry. In addition to printed labels, GT also supplies blank labels on rolls or sheets using various FSC papers and plastic substrates, available with a selection of adhesives from removable to permanent acrylic, permanent hot-melt, and permanent frozen glue.

To add to the company’s reputation for quality work, one of its labels was recently judged Best in Class by EFTA-Benelux. A four-color flexo label cured by LED/UV and printed on a coated stock for “Denner Zartbitter Creme” chocolate won both the Narrow Web and Food Packaging categories at the Awards Ceremony held recently in Antwerp.

Summing up for Mark Andy, Timo Donati, sales manager, adds, “The Benelux region is an important and fast-growing market for Mark Andy, where we have enjoyed great success with our flexo and hybrid presses in recent years. In fact, we have the most installed LED/UV label presses there, which is a tribute to our sales and support personnel, as well as the capability of the technology to earn money for its users. GT Etiketten is a great example of that, and we prize them highly as a customer.”

Asahi to start in-house plate training at Gallus Experience Center

Asahi Photoproducts, a supplier of flexographic photopolymer plate development technology and a subsidiary of the Asahi Kasei Corporation, has reported that the company is starting a new type of operator training courses by combining prepress workflow, platemaking and flexo printing, together with Gallus and Esko, all under one roof.

The first sessions are already planned as part of the Esko MasterClass Series, the first one taking place in March, to feature aspects of flexo workflow and screening technologies, followed by sustainable platemaking production, and then closing the loop by going on-press.

The sessions will be held in the Gallus Experience Center in St. Gallen, Switzerland, which was opened in June of 2023.

“Since our company was founded more than 50 years ago, we have seen several developments in our industry, from ‘potato printing’ to a high-quality flexographic printing process challenging the maximum achievable print quality in our industry today,” says Dieter Niederstadt, Asahi’s technical marketing manager. “Another movement we recognized is the closing of the gap in the platemaking supply chain. Whereas previously many operations, such as file separation, platemaking, and printing, were separated, now with the rising integration of automation, it is easier to bring them together under one roof at the printing converter. This does, however, call for added-value training courses for the next operator generation to come.”


The Gallus Experience Center brings together various industry partners, such as Asahi, Gallus and Esko, to collaborate and drive innovation in the industry. It aims to provide the ideal environment for the platemaking training center, with full end-to-end solutions that support the wider integration of tasks during platemaking operations – with sustainability in mind at every stage. These sessions will provide attendees with hands-on experience with the presented solutions, as well as the ability to ask questions to industry experts and network with peers.

Dario Urbinati, CEO of Gallus Group, comments, “At Gallus, we pride ourselves on driving smart, connected printing – and a key part of this is driving collaboration, bringing the industry together to inspire innovation and transformation. The Gallus Experience Center stands as a testament to this vision, uniting some of the greatest minds across our industry, including our esteemed partners Asahi and Esko, whose expertise enrich our collective journey forward. Together, we are thrilled to host these transformative MasterClass training days, symbolizing our dedication to advancing the industry through shared knowledge and forward-thinking solutions. Join us as we shape the future of printing, charting new horizons and unlocking endless possibilities.”