Greg Hrinya, Editor09.10.21
From motion control and robotics to Industry 4.0 capabilities, label and package printing equipment and software has increasingly become more automated. The pandemic is only placing a greater focus on these burgeoning technologies.
As companies search to find employees to help with their growing businesses, automation provides an opportunity to do more with less. Any predictable or repeatable task performed by a human can now be automated. By automating a label and package printing facility, there exists the potential to create a safer work environment, reduce labor costs, improve efficiencies with higher quality, and improve time to market.
According to Paul Teachout, business development manager of narrow web, Anderson & Vreeland, there is no downside to this rapidly emerging trend. “The benefits of adding automation into your facility are endless,” he says. “Virtually everything in our operation now is driven by software and data collection. This has provided an intelligent environment for our systems to communicate, be monitored and provide data to make better operational decisions. The equipment and processes now have the ability to communicate with us to tell us where we can improve and how to overcome road blocks. This is now the world of IIOT, where our entire production model can work through intelligent operations.”
The ultimate goal for production automation is increased efficiency. For Martin Automatic, that means keeping a label press running non-stop. As Gavin Rittmeyer, VP of sales and marketing, notes, adding automation does not necessarily require a reduction in staff.
“Sometimes there may be a misconception that automation is primarily about headcount reduction. What we see from most of our customers is that automation is more about efficiency in how it allows them to optimize both their equipment and their employees’ skills,” explains Rittmeyer. “As companies instill the values of efficiency and look at non-labor inputs – paper, energy, ink and more – with an analytical eye, they see a bigger picture of automation contributing to both profitability and sustainability. With the shorter runs and more SKUs that customers are expecting from printers and converters, it becomes even more important that efficiency is optimized to the fullest, and the best way to do that is through automation.”
Anderson & Vreeland actively searches for partners that employ automated technologies in their day-to-day operations. From Hybrid Software’s award-winning products, to GMG’s color management tools and the Xeikon Catena plate processing system that offers a zero-touch plate processing solution from imaging to finishing, Anderson & Vreeland has targeted solutions that will help streamline business operations in the future. Plus, Anderson & Vreeland can help in the pressroom with automated anilox cleaning from Eaglewood Technologies, as well as plates and parts cleaners.
“We have adopted automation from almost every level, and we can support fully automated solutions from the front door to the back,” notes Teachout. “Another great opportunity that we have gained tremendous traction on over the past 18 months is our fully-automated Vendor Managed Inventory system driven by RFID software and IIOT. This reduces in-house traffic, lowers transaction costs and ensures you never run out of any consumable. There are countless ways we can help bring automation to operational success.”
Lemu Group, meanwhile, has designed equipment to showcase modularity and seamlessly integrate with existing converting equipment. This enables Lemu Group to operate well with a wide array of equipment.
“The packaging automation aspect of our system can be interfaced with any existing current press and turret, and eliminate the need for extra staff,” says Andre Beaudoin, leader of Lemu Group USA’s sales and marketing team. “There is a solution for virtually any application requirement. While having a standard offering, we have the unique ability to customize the system’s components to address the particular needs of the client. Whether our GTU Glueless Turret Rewinder, interfacing packaging automation to existing converting lines, or a complete turnkey line, there is something to address anyone’s need for improved production.”
Lemu Group’s GTU “roll to box” system can often outpace two flexo presses with automated functions and less manpower, the company says, as it runs at twice the line speed with one operator. This can free up capacity throughout the facility.
“People are caught in a paradigm and say, ‘Well, we’ve always done it this way, so it must be right.’ Maybe we need to rethink the model of how we manufacture,” adds Beaudoin. “The current process works and there’s product going out the door, but companies can’t do that forever. Manufacturing is going to start getting harder because label converters’ customers want more production and they want lower prices. Therefore, you have to start looking at label production from a Lean Manufacturing standpoint and invest in efficient equipment built for today and tomorrow.”
A butt splicer, by its nature, takes what was a series of repeated manual tasks that requires the press to stop producing – watching for the end of the roll, stopping the press, trimming the new and expired webs, applying tape to the top and bottom and so on – and does it automatically without the press stopping or slowing.
“Martin continues to enhance this technology with additional automation on our MBS line of splicers,” says Rittmeyer. “The Waste Reduction System, for example, integrates drive, motor, sensor and control technology to create a system that is superior to an operator at minimizing waste – in some applications, running right down to and even off the core.”
Lemu Group has also teamed with Martin Automatic as its go-to partner. “Most of the plants I’m working with put a Martin Automatic butt splicer on the back end,” states Beaudoin. “By putting a Martin Automatic butt splicer on the end, you don’t even really need to stop the machine. You just need to make sure you’re keeping your ink wells filled and paper is available.”
Delta ModTech has seen automation with its label finishing customers opting for laser diecutting and automated job changeovers. The results have included decreased downtime, less operator interaction, and the ability to monitor raw materials and machine maintenance intervals.
“Integration of on-the-fly cut changes with the use of a barcode reader are becoming popular since they allow for short and long runs, eliminating changeovers,” explains Dave Grenwis, marketing manager, Delta ModTech. “The system reads a barcode printed on the incoming printed substrate, loads the cut profile for that job, and automatically starts diecutting the labels without stoppage, mid roll. This, along with automatic cut to print registration, drastically reduces manual adjustments by the operator and increases production speeds.
“Artificial intelligence in our machine controls is already making the machines smarter, allowing them to detect and correct errors automatically,” he adds. “The prevalence of Industry 4.0 will give converters real-time information on the status of their equipment and on the production and quality of their products.”
Automation, however, is nothing new for Delta ModTech. “We’ve been on the cutting edge of automation since the we introduced the first servo motor controlled converting press,” says Grenwis. “We’ve seen the market demand for more speed, higher accuracy and fewer changeovers. As a machine builder and integration expert, we’ve been continually working to add the newest technologies to help our customers push the limit.”
The company’s ModTech line of equipment allows automation of various processes and works seamlessly with Delta ModTech’s Edge laser technology and MODTrack vision systems, packaging system and conveyors. Delta ModTech also commonly provides OEM integrations of digital printers, robotics, extruders, and end of line
packaging systems.
Changing of the guard
What were once considered disruptive technologies are now a part of the mainstream. More and more label converters are turning to automated production capabilities to better serve their customers, and this trend is increasingly becoming the norm.
By utilizing the newest technologies and prioritizing data, there exists the possibility to attract a new generation of workers – especially as companies begin losing valuable employees to retirement. This new workforce has grown up with technology at their fingertips, and printing is no exception to this trend.
“The printing/converting plants of yesteryear had a reputation, often earned, as dirty, noisy, smelly, unsafe, manually intensive environments. Today’s facilities feature high-tech automation running in bright, clean environments with an emphasis on safety in every plant,” explains Martin Automatic’s Rittmeyer. “This industry allows for the next generation workforce to have a financially satisfying career in an essential business without the heavy debt load of a college degree. Companies that are willing to invest in automation, and in mentoring their employees, will have a win-win scenario. However, if companies don’t have state-of-the-art technology in their plants, they will have a harder time attracting top tier talent.”
“We are part of a very sophisticated, technology-driven industry that will continue to grow to roughly $20 billion by 2025,” comments Anderson & Vreeland’s Teachout. “We need to do a better job of sharing what an appealing, creative and technology-driven industry we are with the younger generation. These systems we now work with are second nature to them. We do not need to search for 30-year veterans anymore. The workforce is out there, and we need to show them that there is a home for them here on a global scale.”
Lemu Group’s GTU system has been specifically designed for one operator, where machines of the past required three – and sometimes more – individuals. “Frankly there are too many people touching the product, and that impedes line speed,” says Lemu Group’s Beaudoin. “In most cases, along with the use of a Martin Automatic butt splicer, the machine can run full speed and virtually never be shut down. From unwind to sealed, addressed, palletized boxes – every shift and every day. On average, we see anywhere from a 35%-60% increase in uptime and output without the need for redundant manpower.”
In the future, this trend will continue to impact label and packaging converters, especially as they realize the opportunities available to their business.
“We will continue to see converters adapt to more automated solutions; it is a must throughout the operation,” explains Teachout. “The digitalization of our entire processes and systems will open new doors for streamlined operations and increased profitability. The automated innovations on the flexo side – both hardware and software – will continue to evolve as they neutralize the effect of the digital proliferation we have seen. Shorter runs will continue to drive our customers’ needs, and our automated operations will be prepared to meet any brand owners’ requirements of cost and speed to market.”
Future trends include modularity and the flexibility to adapt to new and changing demands. Many manufacturers are designing their products with these attributes in mind.
“We have seen a considerable migration toward flexible, modular designs, which is likely to continue into the future,” says Rittmeyer. “Martin has designed mobility and space-saving packages into unwinds and rewinds, which contributes to flexibility. We have also seen in many of the industries into which we supply equipment, a trend toward automating roll-handling functions. We will continue to advance our machinery for optimum performance, developing equipment that complements and enhances other front- and back-end automation.
“The bottom line is: If you want to tinker with old tools, go to your grandpa’s garage. If you want to make your business a Lean and profitable business, invest wisely in good automation and great people to run it,” adds Rittmeyer.
Going beyond the machine
While automation is frequently thought of in terms of robotics and machinery, software has become significantly automated as well. Label Traxx, for example, has developed a core program to always provide an integrated route for a job, from estimating through to accounting.
Recently, however, Label Traxx has expanded its offerings to further promote automated functionality. “On the customer side, Siteline enables repeat customer orders online that drop directly into Label Traxx as a live job ticket waiting to be scheduled,” explains Ken Meinhardt, president of Label Traxx. “Job ticket creation is entirely automated. Siteline is also streamlining the proof approvals process by taking that online and improving the communication between converter and end user.
Batched, meanwhile, is an automated scheduling tool for label printers that sequences job tickets using an advanced algorithm resulting in the best job, on the best machine, at the best time. Batched connects directly to Label Traxx, leveraging a converter’s data to create previously unrealized efficiencies that can add up to big savings in time and money. Batched also includes advanced reports providing insight into capacity planning, real-time order status, key business indicators and more, increasing productivity across all areas of your business.
“It’s an impossible task for a human to consider all the variables necessary to produce an optimized production schedule in real time that also balances customer requirements,” adds Meinhardt. “Batched gives our customers cutting-edge technology to generate an automated and optimized schedule.”
Most printers struggle to optimize the entire planning and scheduling process due to the number of variables that need to be juggled. Changing lead times, machine and labor constraints, machine changeovers and waste all need to be taken into consideration. “With Batched, you establish a set of rules and priorities to tailor the program to your specific manufacturing environment,” he adds. “You customize your machine and labor availability, and Batched generates a real time production schedule for each order and machine based on your priorities. Once the rules are established, generating the complete schedule is automated.”
Label Traxx has also designed its software to be compatible with that of other prepress suppliers. Label Traxx can pass job information over to both Esko Automation Engine and Hybrid Cloudflow to automate step and repeat, both for platemakers and also into digital files to send to press.
“Digital label converters – where orders can contain multiple SKUs of varying quantities – can typically spend a lot of time working out how to arrange labels into files to send to press that minimize the quantity of overs being produced and the amount of splicing required,” remarks Meinhardt. “Label Traxx has a file planning tool to help with that process, and then the file plan can be sent directly to the prepress software via JDF. The stepped file is automatically generated through a pre-defined workflow and passed to the DFE of the press.”
Equipment manufacturers have tailored their units to operate efficiently alongside the latest software, too. “Lemu’s equipment is complete with internal software that can be used as an internal managerial measurement tool that tracks production output. We can also dovetail with most other software tools that are currently being used,” adds Beaudoin. “As software is an ever-changing ‘work in progress,’ this will be assessed during our overall discussion with the client.”
Covid-19 and the workforce
It’s no secret that finding willing and able employees in the manufacturing space has been quite a challenge. The rapid spread of Covid-19 and the fallout of the pandemic have only exacerbated those challenges for label converters.
“In many ways I think the pandemic has possibly taught us how to work smarter and more efficiently,” comments Lemu Group’s Beaudoin. “Lemu’s solution specifically addresses the issue of a lack of technically capable staff or a lack of people wanting to work in general. The issue is that converters cannot fall short on keeping up with demand from their customers due to a shallow or unmotivated workforce.”
According to Delta ModTech’s Grenwis, automation will not be optional in the future. “Automation in manufacturing will be an expectation with the next generation of workers,” he says. “The world around us continues to be more and more automated. If a company isn’t using automation in their processes, they may be seen as antiquated and may be less appealing to future hires.”
For Martin Automatic, the companies that had previously outfitted their plants with automated capabilities were in a stronger position to withstand the difficulties precipitated by the pandemic. “The printers and converters that were considered ‘essential’ businesses and had already incorporated automation fared better through the pandemic than those that were relying more on manual systems,” states Martin Automatic’s Rittmeyer. “These companies had a greater ability to meet production demands, even with uncertainty in the labor force. Supply chain disruptions required customers to manage their inputs even more tightly, something that automation, in terms of efficient use of materials and tighter control over waste, helps them do.”
While businesses took great precaution to protect their employees, they also realized the opportunities available to continue production with less manpower on-site.
“The Covid experience has certainly allowed us to focus on the health and well-being of our employees, customers and partners. It also allowed us to uncover new opportunities to improve our workflows, production equipment and supply chain challenges,” says Anderson & Vreeland’s Teachout. “All of these areas have had automated systems for years, but it was this black swan event that allowed us to see them for the real value they bring. Those who have pursued these automated solutions will be much better for it in the long run, as they will help overcome workforce challenges with reduced personnel, have a safer and healthier work environment and ultimately improve their cost of operation.”
“Everyone wants to work smarter not harder, and automation is a key function in that,” comments Label Traxx’s Ken Meinhardt. “The next generation is growing up in the 4IR – they are used to seamless automation in all aspects of their lives, and they won’t accept repetitive, redundant tasks at work.
“They also want the flexibility to work from home when possible,” Meinhardt adds. “Invest in your systems and automation to make sure you have a working culture that invites new technology and new ways of working. That’s how you will attract the best.”
Xeikon has announced the launch of its brand new XCS Pro 2.0, a fully automated suite of color management tools. The cloud-based XCS Pro 2.0 delivers every advantage of quality color control – predictability, repeatability and profitability, the company says.
The current high levels of e-commerce continue to drive the need for color consistency across the whole print process for brand owners and retailers. The new color package includes training courses plus ongoing consultancy, and it is offered as a “pay as you go” subscription model, making it simple and easy to adopt and utilize.
The new XCS Pro 2.0 is available immediately for demonstration.
“Historically color management software has needed an expert to deliver results,” says Bruce Dransfield, Xeikon’s color management expert. “And this takes time. Xeikon has developed its XCS Pro 2.0 as a ‘no waste,’ ‘no expert’ fully automated color system. Xeikon now has the first digital dry toner, web press solution, which embraces self-fixing color control, quality control and ICC profiling plus Pantone/brand color generation to meet all industry standards. Xeikon has built its new color management system’s architecture to enable it to remotely analyze, target and fix any color problem in minutes. Xeikon’s cloud-based analytical tools can diagnose any color issue, and the issue is remedied with no delays, adding to significant time savings in production.”
Xeikon wants to instill a Lean approach to color management and make it practical for all its customers and users, which offers a host of advantages. The quality control tools can be set to industry standards – either theoretical, process corrected or house standards, and results are measured and traced using the new analytics in Xeikon’s cloud-based system. It is also possible for the operator to fix and re-verify the color quality of the print on the fly.
Meanwhile, Xeikon’s dry toner engines are all fitted with inline spectrophotometers to automatically make this possible during production, saving on waste and rejected jobs. For packaging and label printers, accurate brand colors are vitally important. Xeikon’s new suite of color management software contains tools that can copy and paste from a pre-printed sample to optimize the brand color for the selected substrate. Plus, Xeikon uses .CxF (color exchange format) in order to communicate with tools found in the analog world, such as Flint Group’s VIVO or Pantone LIVE, as well as proofing systems.
As companies search to find employees to help with their growing businesses, automation provides an opportunity to do more with less. Any predictable or repeatable task performed by a human can now be automated. By automating a label and package printing facility, there exists the potential to create a safer work environment, reduce labor costs, improve efficiencies with higher quality, and improve time to market.
According to Paul Teachout, business development manager of narrow web, Anderson & Vreeland, there is no downside to this rapidly emerging trend. “The benefits of adding automation into your facility are endless,” he says. “Virtually everything in our operation now is driven by software and data collection. This has provided an intelligent environment for our systems to communicate, be monitored and provide data to make better operational decisions. The equipment and processes now have the ability to communicate with us to tell us where we can improve and how to overcome road blocks. This is now the world of IIOT, where our entire production model can work through intelligent operations.”
The ultimate goal for production automation is increased efficiency. For Martin Automatic, that means keeping a label press running non-stop. As Gavin Rittmeyer, VP of sales and marketing, notes, adding automation does not necessarily require a reduction in staff.
“Sometimes there may be a misconception that automation is primarily about headcount reduction. What we see from most of our customers is that automation is more about efficiency in how it allows them to optimize both their equipment and their employees’ skills,” explains Rittmeyer. “As companies instill the values of efficiency and look at non-labor inputs – paper, energy, ink and more – with an analytical eye, they see a bigger picture of automation contributing to both profitability and sustainability. With the shorter runs and more SKUs that customers are expecting from printers and converters, it becomes even more important that efficiency is optimized to the fullest, and the best way to do that is through automation.”
Anderson & Vreeland actively searches for partners that employ automated technologies in their day-to-day operations. From Hybrid Software’s award-winning products, to GMG’s color management tools and the Xeikon Catena plate processing system that offers a zero-touch plate processing solution from imaging to finishing, Anderson & Vreeland has targeted solutions that will help streamline business operations in the future. Plus, Anderson & Vreeland can help in the pressroom with automated anilox cleaning from Eaglewood Technologies, as well as plates and parts cleaners.
“We have adopted automation from almost every level, and we can support fully automated solutions from the front door to the back,” notes Teachout. “Another great opportunity that we have gained tremendous traction on over the past 18 months is our fully-automated Vendor Managed Inventory system driven by RFID software and IIOT. This reduces in-house traffic, lowers transaction costs and ensures you never run out of any consumable. There are countless ways we can help bring automation to operational success.”
Lemu Group, meanwhile, has designed equipment to showcase modularity and seamlessly integrate with existing converting equipment. This enables Lemu Group to operate well with a wide array of equipment.
“The packaging automation aspect of our system can be interfaced with any existing current press and turret, and eliminate the need for extra staff,” says Andre Beaudoin, leader of Lemu Group USA’s sales and marketing team. “There is a solution for virtually any application requirement. While having a standard offering, we have the unique ability to customize the system’s components to address the particular needs of the client. Whether our GTU Glueless Turret Rewinder, interfacing packaging automation to existing converting lines, or a complete turnkey line, there is something to address anyone’s need for improved production.”
Lemu Group’s GTU “roll to box” system can often outpace two flexo presses with automated functions and less manpower, the company says, as it runs at twice the line speed with one operator. This can free up capacity throughout the facility.
“People are caught in a paradigm and say, ‘Well, we’ve always done it this way, so it must be right.’ Maybe we need to rethink the model of how we manufacture,” adds Beaudoin. “The current process works and there’s product going out the door, but companies can’t do that forever. Manufacturing is going to start getting harder because label converters’ customers want more production and they want lower prices. Therefore, you have to start looking at label production from a Lean Manufacturing standpoint and invest in efficient equipment built for today and tomorrow.”
A butt splicer, by its nature, takes what was a series of repeated manual tasks that requires the press to stop producing – watching for the end of the roll, stopping the press, trimming the new and expired webs, applying tape to the top and bottom and so on – and does it automatically without the press stopping or slowing.
“Martin continues to enhance this technology with additional automation on our MBS line of splicers,” says Rittmeyer. “The Waste Reduction System, for example, integrates drive, motor, sensor and control technology to create a system that is superior to an operator at minimizing waste – in some applications, running right down to and even off the core.”
Lemu Group has also teamed with Martin Automatic as its go-to partner. “Most of the plants I’m working with put a Martin Automatic butt splicer on the back end,” states Beaudoin. “By putting a Martin Automatic butt splicer on the end, you don’t even really need to stop the machine. You just need to make sure you’re keeping your ink wells filled and paper is available.”
Delta ModTech has seen automation with its label finishing customers opting for laser diecutting and automated job changeovers. The results have included decreased downtime, less operator interaction, and the ability to monitor raw materials and machine maintenance intervals.
“Integration of on-the-fly cut changes with the use of a barcode reader are becoming popular since they allow for short and long runs, eliminating changeovers,” explains Dave Grenwis, marketing manager, Delta ModTech. “The system reads a barcode printed on the incoming printed substrate, loads the cut profile for that job, and automatically starts diecutting the labels without stoppage, mid roll. This, along with automatic cut to print registration, drastically reduces manual adjustments by the operator and increases production speeds.
“Artificial intelligence in our machine controls is already making the machines smarter, allowing them to detect and correct errors automatically,” he adds. “The prevalence of Industry 4.0 will give converters real-time information on the status of their equipment and on the production and quality of their products.”
Automation, however, is nothing new for Delta ModTech. “We’ve been on the cutting edge of automation since the we introduced the first servo motor controlled converting press,” says Grenwis. “We’ve seen the market demand for more speed, higher accuracy and fewer changeovers. As a machine builder and integration expert, we’ve been continually working to add the newest technologies to help our customers push the limit.”
The company’s ModTech line of equipment allows automation of various processes and works seamlessly with Delta ModTech’s Edge laser technology and MODTrack vision systems, packaging system and conveyors. Delta ModTech also commonly provides OEM integrations of digital printers, robotics, extruders, and end of line
packaging systems.
Changing of the guard
What were once considered disruptive technologies are now a part of the mainstream. More and more label converters are turning to automated production capabilities to better serve their customers, and this trend is increasingly becoming the norm.
By utilizing the newest technologies and prioritizing data, there exists the possibility to attract a new generation of workers – especially as companies begin losing valuable employees to retirement. This new workforce has grown up with technology at their fingertips, and printing is no exception to this trend.
“The printing/converting plants of yesteryear had a reputation, often earned, as dirty, noisy, smelly, unsafe, manually intensive environments. Today’s facilities feature high-tech automation running in bright, clean environments with an emphasis on safety in every plant,” explains Martin Automatic’s Rittmeyer. “This industry allows for the next generation workforce to have a financially satisfying career in an essential business without the heavy debt load of a college degree. Companies that are willing to invest in automation, and in mentoring their employees, will have a win-win scenario. However, if companies don’t have state-of-the-art technology in their plants, they will have a harder time attracting top tier talent.”
“We are part of a very sophisticated, technology-driven industry that will continue to grow to roughly $20 billion by 2025,” comments Anderson & Vreeland’s Teachout. “We need to do a better job of sharing what an appealing, creative and technology-driven industry we are with the younger generation. These systems we now work with are second nature to them. We do not need to search for 30-year veterans anymore. The workforce is out there, and we need to show them that there is a home for them here on a global scale.”
Lemu Group’s GTU system has been specifically designed for one operator, where machines of the past required three – and sometimes more – individuals. “Frankly there are too many people touching the product, and that impedes line speed,” says Lemu Group’s Beaudoin. “In most cases, along with the use of a Martin Automatic butt splicer, the machine can run full speed and virtually never be shut down. From unwind to sealed, addressed, palletized boxes – every shift and every day. On average, we see anywhere from a 35%-60% increase in uptime and output without the need for redundant manpower.”
In the future, this trend will continue to impact label and packaging converters, especially as they realize the opportunities available to their business.
“We will continue to see converters adapt to more automated solutions; it is a must throughout the operation,” explains Teachout. “The digitalization of our entire processes and systems will open new doors for streamlined operations and increased profitability. The automated innovations on the flexo side – both hardware and software – will continue to evolve as they neutralize the effect of the digital proliferation we have seen. Shorter runs will continue to drive our customers’ needs, and our automated operations will be prepared to meet any brand owners’ requirements of cost and speed to market.”
Future trends include modularity and the flexibility to adapt to new and changing demands. Many manufacturers are designing their products with these attributes in mind.
“We have seen a considerable migration toward flexible, modular designs, which is likely to continue into the future,” says Rittmeyer. “Martin has designed mobility and space-saving packages into unwinds and rewinds, which contributes to flexibility. We have also seen in many of the industries into which we supply equipment, a trend toward automating roll-handling functions. We will continue to advance our machinery for optimum performance, developing equipment that complements and enhances other front- and back-end automation.
“The bottom line is: If you want to tinker with old tools, go to your grandpa’s garage. If you want to make your business a Lean and profitable business, invest wisely in good automation and great people to run it,” adds Rittmeyer.
Going beyond the machine
While automation is frequently thought of in terms of robotics and machinery, software has become significantly automated as well. Label Traxx, for example, has developed a core program to always provide an integrated route for a job, from estimating through to accounting.
Recently, however, Label Traxx has expanded its offerings to further promote automated functionality. “On the customer side, Siteline enables repeat customer orders online that drop directly into Label Traxx as a live job ticket waiting to be scheduled,” explains Ken Meinhardt, president of Label Traxx. “Job ticket creation is entirely automated. Siteline is also streamlining the proof approvals process by taking that online and improving the communication between converter and end user.
Batched, meanwhile, is an automated scheduling tool for label printers that sequences job tickets using an advanced algorithm resulting in the best job, on the best machine, at the best time. Batched connects directly to Label Traxx, leveraging a converter’s data to create previously unrealized efficiencies that can add up to big savings in time and money. Batched also includes advanced reports providing insight into capacity planning, real-time order status, key business indicators and more, increasing productivity across all areas of your business.
“It’s an impossible task for a human to consider all the variables necessary to produce an optimized production schedule in real time that also balances customer requirements,” adds Meinhardt. “Batched gives our customers cutting-edge technology to generate an automated and optimized schedule.”
Most printers struggle to optimize the entire planning and scheduling process due to the number of variables that need to be juggled. Changing lead times, machine and labor constraints, machine changeovers and waste all need to be taken into consideration. “With Batched, you establish a set of rules and priorities to tailor the program to your specific manufacturing environment,” he adds. “You customize your machine and labor availability, and Batched generates a real time production schedule for each order and machine based on your priorities. Once the rules are established, generating the complete schedule is automated.”
Label Traxx has also designed its software to be compatible with that of other prepress suppliers. Label Traxx can pass job information over to both Esko Automation Engine and Hybrid Cloudflow to automate step and repeat, both for platemakers and also into digital files to send to press.
“Digital label converters – where orders can contain multiple SKUs of varying quantities – can typically spend a lot of time working out how to arrange labels into files to send to press that minimize the quantity of overs being produced and the amount of splicing required,” remarks Meinhardt. “Label Traxx has a file planning tool to help with that process, and then the file plan can be sent directly to the prepress software via JDF. The stepped file is automatically generated through a pre-defined workflow and passed to the DFE of the press.”
Equipment manufacturers have tailored their units to operate efficiently alongside the latest software, too. “Lemu’s equipment is complete with internal software that can be used as an internal managerial measurement tool that tracks production output. We can also dovetail with most other software tools that are currently being used,” adds Beaudoin. “As software is an ever-changing ‘work in progress,’ this will be assessed during our overall discussion with the client.”
Covid-19 and the workforce
It’s no secret that finding willing and able employees in the manufacturing space has been quite a challenge. The rapid spread of Covid-19 and the fallout of the pandemic have only exacerbated those challenges for label converters.
“In many ways I think the pandemic has possibly taught us how to work smarter and more efficiently,” comments Lemu Group’s Beaudoin. “Lemu’s solution specifically addresses the issue of a lack of technically capable staff or a lack of people wanting to work in general. The issue is that converters cannot fall short on keeping up with demand from their customers due to a shallow or unmotivated workforce.”
According to Delta ModTech’s Grenwis, automation will not be optional in the future. “Automation in manufacturing will be an expectation with the next generation of workers,” he says. “The world around us continues to be more and more automated. If a company isn’t using automation in their processes, they may be seen as antiquated and may be less appealing to future hires.”
For Martin Automatic, the companies that had previously outfitted their plants with automated capabilities were in a stronger position to withstand the difficulties precipitated by the pandemic. “The printers and converters that were considered ‘essential’ businesses and had already incorporated automation fared better through the pandemic than those that were relying more on manual systems,” states Martin Automatic’s Rittmeyer. “These companies had a greater ability to meet production demands, even with uncertainty in the labor force. Supply chain disruptions required customers to manage their inputs even more tightly, something that automation, in terms of efficient use of materials and tighter control over waste, helps them do.”
While businesses took great precaution to protect their employees, they also realized the opportunities available to continue production with less manpower on-site.
“The Covid experience has certainly allowed us to focus on the health and well-being of our employees, customers and partners. It also allowed us to uncover new opportunities to improve our workflows, production equipment and supply chain challenges,” says Anderson & Vreeland’s Teachout. “All of these areas have had automated systems for years, but it was this black swan event that allowed us to see them for the real value they bring. Those who have pursued these automated solutions will be much better for it in the long run, as they will help overcome workforce challenges with reduced personnel, have a safer and healthier work environment and ultimately improve their cost of operation.”
“Everyone wants to work smarter not harder, and automation is a key function in that,” comments Label Traxx’s Ken Meinhardt. “The next generation is growing up in the 4IR – they are used to seamless automation in all aspects of their lives, and they won’t accept repetitive, redundant tasks at work.
“They also want the flexibility to work from home when possible,” Meinhardt adds. “Invest in your systems and automation to make sure you have a working culture that invites new technology and new ways of working. That’s how you will attract the best.”
Xeikon has announced the launch of its brand new XCS Pro 2.0, a fully automated suite of color management tools. The cloud-based XCS Pro 2.0 delivers every advantage of quality color control – predictability, repeatability and profitability, the company says.
The current high levels of e-commerce continue to drive the need for color consistency across the whole print process for brand owners and retailers. The new color package includes training courses plus ongoing consultancy, and it is offered as a “pay as you go” subscription model, making it simple and easy to adopt and utilize.
The new XCS Pro 2.0 is available immediately for demonstration.
“Historically color management software has needed an expert to deliver results,” says Bruce Dransfield, Xeikon’s color management expert. “And this takes time. Xeikon has developed its XCS Pro 2.0 as a ‘no waste,’ ‘no expert’ fully automated color system. Xeikon now has the first digital dry toner, web press solution, which embraces self-fixing color control, quality control and ICC profiling plus Pantone/brand color generation to meet all industry standards. Xeikon has built its new color management system’s architecture to enable it to remotely analyze, target and fix any color problem in minutes. Xeikon’s cloud-based analytical tools can diagnose any color issue, and the issue is remedied with no delays, adding to significant time savings in production.”
Xeikon wants to instill a Lean approach to color management and make it practical for all its customers and users, which offers a host of advantages. The quality control tools can be set to industry standards – either theoretical, process corrected or house standards, and results are measured and traced using the new analytics in Xeikon’s cloud-based system. It is also possible for the operator to fix and re-verify the color quality of the print on the fly.
Meanwhile, Xeikon’s dry toner engines are all fitted with inline spectrophotometers to automatically make this possible during production, saving on waste and rejected jobs. For packaging and label printers, accurate brand colors are vitally important. Xeikon’s new suite of color management software contains tools that can copy and paste from a pre-printed sample to optimize the brand color for the selected substrate. Plus, Xeikon uses .CxF (color exchange format) in order to communicate with tools found in the analog world, such as Flint Group’s VIVO or Pantone LIVE, as well as proofing systems.
