While much has been made about new printing technologies, flexography still dominates label and package printing. The modernization of this analog printing process will keep the technology booming for years to come, too.

Flexography has evolved from a manual artform to a technological powerhouse. Automation and data now play a huge role in shaping converters’ print runs. 

According to Nilpeter, flexo represents the backbone of global label production, and that will continue. “The most significant trend we see is the shift from manual operation to intelligent manufacturing,” states Martin Teilberg, global head of marketing, Nilpeter. “Flexo today is no longer a mechanical discipline alone – it is increasingly software-driven. Automation has moved from being a competitive advantage to becoming an operational necessity. We see strong demand for automated registration, closed-loop color control, servo-driven platforms, automatic job recall, and fast, predictable changeovers.”

“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,” adds Paul Teachout, business development, Omet Americas. “Digitalization creates data-driven, predictive modeling of our workflows. Our products must transform the way companies monitor, manage, and interact with their machines, enhancing efficiency, productivity, and technical support.”

Flexo is evolving quickly, meaning presses are also providing more packaging types. “Web widths are shifting – digital continues to absorb ultra-short-run label work, while wider inline flexo is gaining traction across unsupported labels, flexible packaging, and specialty applications,” states Katie Graham, regional marketing and communications manager, Bobst North America. “Increasingly, converters are also leveraging data and AI-driven insights to simplify operations and optimize performance.”

Technology has advanced to keep up with the latest challenges facing converters today. “Flexo converters are facing many of the same pressures we see across the wider label industry,” comments Werner Krummenacher, Gallus sales head, Market Region Americas. “Flexibility is becoming increasingly important, with businesses looking for platforms that can evolve with them over time, giving them the confidence that their investment will continue to deliver value as market requirements change.  At the same time, margins remain under pressure. That makes efficiency and productivity on the shop floor more critical than ever. The ability to run complex jobs with fewer manual interventions, and with greater consistency, is becoming a key factor in maintaining profitability, which is why we’re seeing increasing demand from customers around automation, ease of use, and faster setup.”

For many of the industry’s leading converters, flexo is still paramount across their operations. Inovar Packaging Group, for example, relies on flexo across numerous sites. “Flexo is still our most efficient platform for longer runs and repeat programs,” explains Brent Berthiaume, director, Prepress & Color Control, Inovar Packaging Group. “It is ideal when brands scale up from digital volumes. Plus, flexo is the best option when coatings, specialty finishes, or durability matter. It’s important to note flexo works alongside digital instead of competing with it.”

Converters are increasingly relying on real-time data to optimize their companies, especially with respect to their flexo runs. “Our customers want actionable production data in real time – not just machine statistics, but insights that support better decision-making,” adds Teilberg. “Through collaborations, such as our work with Catapult Print, we have seen how structured data collection leads to measurable improvements in uptime, reduced waste, and more consistent output. The goal is simple: keep the press running and eliminate
unplanned downtime.”

The newest flexo presses can also serve numerous markets. “One of the major trends we’re seeing is traditional label converters using flexo as a springboard into adjacent print formats, especially flexible packaging,” says Ben Luly, product manager, Mark Andy. “A half decade ago, for many label converters that felt like a big leap. Now, it’s increasingly part of the growth plan, and flexo remains a practical way to expand into films and new structures with the right configuration and workflow.  

“We’re also seeing steady interest in short-run shrink applications,” adds Luly. “That space has matured. Converters are getting more deliberate about where shrink fits in their production mix, and they’re looking for equipment and processes that let them handle it profitably.”

Despite the massive improvements in flexo technology, suppliers like Nilpeter and Bobst have emphasized modularity with their newest launches. “Our presses are built for long service life,” comments Teilberg. “Many of our installations operate successfully for decades. For that reason, we also invest heavily in upgrade programs, bringing the latest software, controls, and hardware improvements to machines already in the field. This protects our customers’ investments, enhances performance, and extends operational lifetime without necessarily replacing the entire press.”

“New-generation presses deliver higher levels of automation, connectivity, and flexibility, helping reduce complexity across the entire production workflow,” adds Graham. “Modular platforms, such as those from Bobst, allow converters to integrate multiple processes into one line, streamlining operations from job setup through to production and performance monitoring.”

From a press performance standpoint, LED curing is another popular trend. LED curing supports more energy-efficient production, reduces running costs, and can contribute to a lower total cost of ownership while also supporting sustainability goals. 

“We design our platforms with this flexibility in mind,” says Krummenacher. “On the Gallus RCS platform, for example, existing curing units can be retrofitted with switchable LED devices. While on the Gallus Labelmaster platform, customers can choose between mercury and LED curing depending on the inks and varnishes they wish to use. This allows converters to select the curing technology that best fits their applications while expanding the range of compatible inks.”

Suppliers have also diversified their portfolios to a place where they can work with customers on finding the right technology for their book of business. For example, Mark Andy offers flexo, digital, and hybrid press solutions.

“We can help a converter think through what’s best for their business, their customer mix, and their operational realities without steering them toward one technology just because it’s the only one we can offer,” says Luly. “Some converters want to stay in flexo because they’re excellent at it, they have a disciplined process, and they don’t want to add complexity or technical risk that they’re not staffed to manage. That can be a smart choice. Others have the strategy and the internal capabilities to take the next step into hybrid or digital because it aligns with where their customers are going.”

“At Gallus, we believe the future of label production will not be defined by a single technology,” adds Krummenacher. “There’s undoubtedly a place for conventional, digital, and hybrid solutions, and as the lines between these technologies become increasingly blurred, having expertise across all of them is essential to help customers identify the most suitable and profitable production approach.”

Redefining the pressroom

Even in recent years, there has been a misconception that a label converter had to choose digital or flexo for their print shop. These technologies work side by side, and selecting the right print method is key to optimizing efficiency. The evolution of both technologies – along with the emergence of hybrid – has altered the dynamic of the pressroom.

“Digital continues to own short runs and versioning,” notes Inovar’s Berthiaume. “Meanwhile, flexo has had to get faster at setup to stay competitive, with quicker make-ready and changeovers. Hybrid production is more common, with digital for variable data and flexo for speed and cost efficiency. Customers expect tighter color matching between both platforms now.”

“Flexo is moving toward more versatile, high-value production – complementing digital while simplifying the overall production mix and enabling converters to handle multiple applications on a single platform,” adds Bobst’s Graham.

Digital and hybrid printing have reshaped the allocation of work across a label printing facility, too. Speed plays a major role here.

“High-speed digital continues to push into job lengths that were historically ‘safe’ flexo territory, and that crossover point has moved substantially as digital speeds have increased,” states Mark Andy’s Luly. “Flexo has lost share in certain segments, particularly shorter runs with high versioning. However, the bigger impact is the way converters define efficiency now. The conversation used to be very focused on ink cost and raw speed. Today, it’s more about total throughput and how quickly you can move jobs from the order received to labels on a pallet shipped out the door.”

However, what was once considered a digital or flexo run is constantly evolving. Digital and hybrid presses can run longer. Therefore, collaboration with suppliers is critical when it comes to  choosing the right press for the targeted book of business.

“What’s clear is that run lengths are continuing to shorten and the break-even point for digital production is evolving,” says Gallus’ Krummenacher. “That means digital is becoming viable for a wider range of applications than it was just a few years ago, which naturally begins to blur the lines between technologies. In the short to medium term, this will likely accelerate the adoption of hybrid approaches – either through integrated presses that combine flexo and digital within a single system, or through a broader ‘hybrid’ printshop floor and production mindset, where converters have the flexibility to choose the right technology for each job.”

Converters must account for numerous variables when estimating a job, from setup times and platemaking bottlenecks to changeovers and troubleshooting. The ability to run consistently – job after job – will dictate success.

Hybrid, meanwhile, offers the best of both worlds. “Hybrid sits in a middle ground for a lot of converters,” adds Luly. “It allows them to keep flexo where it’s strongest, bring in digital where it adds value, and avoid forcing every job into one lane. That flexibility has changed the buying mindset. Converters are building pressrooms around production strategies, not around a single print process.”

“There is room for digital, hybrid, and flexo,” adds Nilpeter’s Teilberg. “The optimal choice depends entirely on the converter’s business model, run lengths, substrate mix, and customer requirements.”

Omet, for example, has partnered with Durst for its hybrid solutions. For the short and mid-run length jobs, hybrid presses deliver a 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.

“Over the years, I have seen printers have up to 25-30% of their production be short run work, and printers struggled with quick-turns on traditional flexo presses where they needed to push out 12 jobs a day,” explains Omet’s Teachout. “The digital hybrid solutions of today have helped overcome that challenge. We have seen over the last decade that hybrid presses 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.”

When investing in a new press, Inovar has several requirements in mind. “We’re looking for automation that actually reduces setup time, with automated impression, registration, and more,” adds Berthiaume. “Reliable color control systems, such as ink metering, anilox and tape systems, are critical, as well. Ultimately, we need press data that helps us track performance and reduce downtime.”

Focusing on the workforce

The workforce challenges facing the label manufacturing industry continue to loom large. The advancements of flexo will play a critical role in hiring and retaining employees, especially as long-time flexo press operators retire from the workforce. Suppliers are designing presses that will attract today’s future flexographers.

“Ease of use is critical,” says Bobst’s Graham. “Modern presses are designed with intuitive interfaces, guided workflows, and connected technologies that reduce operator dependency and simplify day-to-day operations, making the production environment more accessible and efficient.”

“New technologies offer relief to the growing workforce challenge,” adds Omet’s 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.

“A big part of attracting the younger generation to our trade is to convince them that this is not a down and dirty manufacturing process of the past, but that of a very sophisticated, clean-hand production process utilizing the most advanced technologies in the world,” continues Teachout. “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. Simply put, we are entering the next industrial age, from 4.0 to 5.0 and from disruptive to regenerative.”

In most cases, the prospective employee anticipates a technology-friendly process. “The next generation expects intuitive systems, digital interfaces, and connected environments,” says Nilpeter’s Teilberg. “Modern flexo presses reflect that. Touchscreen interfaces, recipe-driven job setup, remote diagnostics, and integrated data dashboards make the press environment more accessible and less dependent on manual adjustments. Young professionals are attracted to technology that feels advanced. Automation, AI-driven optimization, and data-based decision-making make flexographic production more aligned with modern industrial engineering.”

Technology now is the name of the game with the newest flexographic innovations, especially with the difficulty in recruiting new employees. “Hiring is hard, training is harder, and retention is a real issue,” explains Mark Andy’s Luly. “In a lot of pressrooms, tribal knowledge is walking out the door, and the next generation of operators often hasn’t had the same apprenticeship-style runway that earlier generations had. That reality is directly shaping equipment requirements.”

Therefore, the newest press technology must reduce the dependency on “the one person who knows how to run that press,” adds Luly. More automation, fewer manual steps, and fewer opportunities for variation make it easier to train people, maintain consistency, and run at a high level across multiple shifts. The workflow must also become more intuitive and repeatable. 

For Inovar, the newest flexographic technology makes training a simpler and more intuitive process. “It feels more like running a technical system than purely mechanical equipment,” says Berthiaume. “They are easier to train on now compared to older presses. There are cleaner setups and fewer manual tweaks with quick change die systems, for example. And there are more screen-based (digital) controls and less mechanical adjustments such as buttons vs. knobs.”

However, technology can’t be the only solution. While collaboration is often discussed, it needs to happen within converting facilities, as well as between suppliers and customers.

“Attracting the next generation is not only about new technology – it’s also about ensuring knowledge is passed on,” states Gallus’ Krummenacher. “As the industry prepares to hand the baton to the next generation of press operators, it’s crucial that we continue transferring technical expertise and best practices. That is why we established the Gallus Print Academy, which provides ongoing training and education to help customer teams maximize the performance of their equipment and build the skills needed for the future. Together, these elements form part of our broader vision for smart, connected printing – creating production environments that are not only more efficient and automated but also supported by continuous learning and collaboration across the industry.”

In order to continue grappling with this challenge, technology will need to improve – but so too must the efforts of suppliers and converters in touting the industry. “The challenge has been and will continue to be recruitment and retainment,” comments Teachout. “We must entertain the next generation workforce in their decision-making years – in high school, supporting career days and apprenticeship programs to share our industry and all the opportunities it has to offer. This needs to be done at the grass roots level. If there’s 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.”

Flexographic innovation

Bobst continues to focus on solutions that connect workflow, equipment, and data. The company’s newest presses and technology reduce complexity across the full lifecycle, from file to finished product and beyond. The goal is simple: enable converters to make faster decisions, run more efficiently, and scale with confidence.

As a supplier of flexographic and digital/hybrid solutions, Gallus is focused on continuing to evolve its flexographic platforms while also advancing its broader portfolio. This ensures customers have access to the right solutions, whichever direction the market takes them.

“This fits closely with our System to Compose concept, which allows customers the flexibility to expand their production setups over time, for example by incorporating digital printing units alongside conventional processes where it adds value,” remarks Gallus’ Krummenacher. “A good example of development in the flexo space is the continued success and evolution of the Gallus Labelmaster. With the recent addition of the 22″ configuration, converters can now achieve even higher productivity, particularly in sleeve applications and high-volume label production.

“We are working to change mindsets, and to integrate conventional, hybrid and digital technologies into more intelligent, connected production workflows and ecosystems,” adds Krummenacher. “By combining advanced workflow solutions, such as Heidelberg Prinect, converters can gain greater visibility, automation and efficiency across their entire production environment.”  

Meanwhile, Mark Andy is helping converters simplify decisions and reduce variability in the pressroom.The company has highlighted an automation strategy, SmartSet, which is designed to reduce setup complexity and help converters improve throughput by minimizing touchpoints and making changeovers more efficient and consistent. This type of automation targets the constraints converters are dealing with: fewer experienced operators, compressed lead times, more job variety, and the need to keep presses running predictably day after day.

“Mark Andy’s newest press platforms also reflect how converters are evolving their production mix,” says Luly. “The Performance Series S9 flexo press is built for those who need high-speed label productivity but also want a press that can support expansion into mid-web flexible packaging and unsupported film applications, with performance designed to handle both traditional label work and the demands that come with more challenging substrates at speeds of up to 1,000 fpm.”

Nilpeter continues to refine intelligent registration systems, automated color control, advanced servo technology, and faster changeover procedures. These directly improve uptime and reduce waste.  

“Within data and connectivity, we support enhanced machine data capture and integration with customer workflows,” notes Nilpeter’s Teilberg. “Experience from projects such as Catapult Print demonstrates that structured data use translates into real operational savings.”

Omet is committed to providing the most advanced narrow and mid-web packaging platforms available that can adapt and evolve with growing technologies. 

“On the software side, the digitalization and connectivity we offer has set the bar in predictive production modeling,” states Teachout. “Connectivity to external systems with specifically designed industrial machinery software is crucial.”

Plus, Omet Virtual Access is a multilingual app used for the management of maintenance and assistance activities and remote installations. Tasker, meanwhile, manages production jobs with greater simplicity and agility, ensuring better integration with MIS/ERP systems, defining the new connectivity standard between Omet machines and customer industrial systems. The Omet Job Card Manager is cloud-based software that manages recipes on the machine in a unified manner, distributing them among all groups so as not to lose them in case of PC or machine damage.

As the flexible packaging market represents more than 40% of all flexo-produced packaging, Omet offerings begin at 14″ and go all the way through to 42″ in width.

“Our new KFlex, launched at Labelexpo Europe, also displayed our new Switch platform,” adds Teachout. “This is a convertible platform that allows you to switch modules within the press from flexo to offset to rotary screen or even a die station, making this the most convertible press in the market and ideal for hybrid solutions.”