Greg Hrinya, Editor04.04.24
The term “game-changing” has been casually thrown around for many years, especially regarding new label and package printing product launches. In theory, every product has the potential to positively impact a label printing business, making the phrase overused. However, the advent of automated converting equipment really does fit the bill. Why? Because many of today’s converters don’t have the workforce to tackle the work flowing into print shops.
Converters that L&NW talks to cite automation as one of the industry’s hottest trends – mainly out of necessity. Horror stories about labor shortages abound, but new R&D has enabled converters to do more with less. And for those facilities not lacking in manpower, those employees can be assigned to more mission-critical areas of the business.
How, exactly, does automated converting equipment simplify the life of a label printer? According to James Brennan, sales executive, A B Graphic International (ABG), automation accomplishes many tasks.
“Automation reduces the reliance on skilled operators during a job change,” says Brennan. “It simplifies the job change process for operators down to as little as scanning a QR code, which can load all data into an HMI and then automatically sets the turret, camera, slitting, back scoring, flexo initiation and more – depending on spec. By simplifying job changes, lower skilled staff are required, and converters can perform SKU changes on the fly without stopping the run or requiring operator intervention. Overall, there is reduced downtime and waste.”
“The advancements in automation technology have revolutionized the label printing industry, improving efficiency, accuracy, and productivity,” adds Chiara Prati, CEO and CSO, Prati. “One major change brought about by automation is the integration of digital printing technology into label converting equipment. Digital printing allows for faster setup times, reduced waste, and the ability to print variable data and customized labels on-demand.”
Automation is not limited to one machine or computer system, either. Much of a label printing shop’s operations can be streamlined and optimized with the newest technological capabilities.
“I am already speaking to people who are interested in automating their entire plant with control of a single computer or workstation,” explains Andre Beaudoin, director of North American sales and marketing, LemuGroup. “The impact on the industry is – and will become even more – needed and vital. As the needs of the individual converter vary, so will the level of automation required by each.”
The proof is out there, too. For example, Mercian Labels improved its finishing efficiency by 74% with an ABG Connect Digicon Series 3 compared to its previous two-step process. “ABG Connect is an automated revolution,” states Adrian Steele, managing director, Mercian Labels.”
“Converters are excited, and their expectations are increasing because automation can ease their processing and allow them to save on production costs, waste, and energy,” says Virgilio Micale, director of sales, Cartes. “Today, one of the biggest challenges for any converter is to keep operational personnel stability in the company, so automation is very helpful to have new entries trained in a short period of time.”
The Martin Automatic team touting automation at Labelexpo Europe.
For the vast majority of companies, automation is not a luxury. With staffing problems and increasing orders – with expected short turnaround times – automation is the wave of the future.
“Automation is here to stay and has now become the most needed piece of equipment in the pressroom today,” comments Beaudoin. “As our need for skilled labor has diminished, the need for end of line automation that allows for complete roll to sealed and palletized box has taken over. End of line automation has now become an accepted competitive edge in label converting.”
Converters have sought out LemuGroup to employ end of line automation to replace the missing shop workers who completed the packaging at the end of the press line to keep customers supplied with labels. A lack of staff has not led to diminished returns, thanks to the newest automated converting equipment.
“Our customers have since found that their production rates increased substantially – 30-50% – with a single operator,” says Beaudoin. “Overhead is reduced and production has shot through the roof. We have a large number of installations in the United States where this has become the standard end result. Our system is capable of working with any press or converting system currently owned.”
Sustainability is also a significant reason to automate production processes. With brands and consumers becoming ever more discerning about the environment, there is an inherent sustainability element to automated converting equipment.
“Automating the web fed process helps converters manage exposure to these increasing costs by reducing waste and increasing the meters of useable labels and packaging per unit of input – reducing waste and increasing productivity is more important now than ever before,” explains Gavin Rittmeyer, VP of sales and marketing, Martin Automatic. “Lending to this trend is the drive to produce materials with less content – thinner films take less petroleum to produce; recycled materials do not consume virgin pulp resources and linerless labels eliminate an entire web altogether, and yet adds the complexity of transporting web with exposed adhesive through the process.”
In the future, the proliferation of automated converting equipment will only continue. “As we look toward the future, the role of automation and robotics in managing material flows within factories will also become increasingly prominent,” states Haim Levit, SVP and division president, HP Industrial Print. “Accurate and real-time records of everything entering and leaving the production floor are critical, and as we look forward, we can expect the ERPs of printing companies will increasingly integrate traceability of these elements and finished products more efficiently, from the moment they leave the machines to the warehouse or the reconciliation area for swift shipping.
“With digitalization, automation, and AI-driven optimization at the forefront, the industry is poised to enter a new era of quality, versatility, productivity, sustainability, and profitability,” adds Levit.
“The learning curve process is now very short since automation practically cancels out almost all variables where operational errors were the main issue,” adds Cartes’ Micale. “We believe that in the coming years the automation of processes will continue to grow exponentially.”
The engineering style also plays a role in attracting the next-generation workforce. Therefore, automation is required for tomorrow’s manufacturing employees. “We have succeeded in decreasing the learning time to get to know and start the machine, and we do this by ‘guiding’ new operators step by step on the machine, in the name of maximum safety,” notes Prati. “And since tomorrow’s operators are the kids who study and play in digital worlds today, we are adopting the concepts of gamification to make ourselves better understood.”
In addition to workforce, quality is another main driver for implementing automation in a converting business. “The ultimate objective is to achieve the buyer’s attention, which has led to products being differentiated in several ways,” adds Micale. “Equipment manufacturers have kept pace with the technological changes to develop new ways to diversify a product through the enhancement of its contained elements, often applied on labels and packaging.”
LemuGroup’s automated capabilities draw a crowd.
Martin Automatic has a very simple philosophy in place to help train new operators. “Martin focuses on equipment designs based on the 4Es: Equipment that is Easy to use, Easy to understand, Easy to maintain, and Easy to integrate – the 4Es of Martin,” states Rittmeyer. “Our commitment to KIS – Keep It Simple – and pure-form, essential engineering, allows us to minimize the time it takes to get operators proficient on our equipment.”
According to Beaudoin, LemuGroup’s customers have been quite satisfied with the returns and ease of use. In many cases, they’re placing repeat orders to further automate their plants. After investigating the new technology, they are usually sold.
“Feedback from our clients has been outstanding, and most of them are already processing second and third systems or are in the process of modifying their systems to accommodate packaging product from multiple print or converting lines,” states Beaudoin. “Once converters see the system in action, they are thrilled with the high level of efficiency and fast ROI this technology provides. Less people also means fewer insurance claims and zero wasted downtime. As one owner stated, ‘This takes us out of the HR game and back into what we do’.”
“Converters appreciate the reduction in human errors associated with manual roll changes and tension adjustments, leading to more resilient and sustainable production environments,” adds Rittmeyer. “The equipment’s user-friendly design and seamless integration with press lines have garnered praise, contributing to enhanced productivity and cost-efficiency.”
Automation allows Cartes to deliver high-quality finishing.
ABG offers a wide range of automated functions for label converters. ABG Connect is the company’s automated workflow product, which sets up jobs automatically by integrating the finishing machines with an MIS or workflow product. This technology is applicable to the Digicon Series 3, DigiLite, Converter DigiLase, Vectra and SRI.
“ABG Connect is retrofittable to Digicon Series 3 and DigiLite,” says Brennan. “ABG also offers fleyeVision and Zeropoint technology for automatic, operator-free inspection setup. DigiLase, meanwhile, features automated, instant job changeovers. And DigiJet enables automated digital embellishment, with cold foil and spot varnish – coming soon.”
Plus, manufacturers will establish partnerships to further streamline a label converter’s capabilities. “In the future, we expect to see the continued expansion of machinery automation and partner integrations such as CERM,” adds ABG’s Brennan. “ABG also now has partnerships with Hybrid Software and a soon to be announced partnership with Esko.”
Cartes’ R&D has been centered around mechanical strength of machinery, precision and high production speeds. Additionally, the company has strived to provide technologies that achieve the highest quality of final products.
“Our latest technology is the Jet D-Screen (JDS), a digital screen-printing unit to create high raised embellishment,” explains Micale. “We can also add hot foil transferring, a ‘metal doming’ effect, which is completed with a fully automated concept where laser converting, auto-slitting, and rewinding are part of the configuration.”
LemuGroup, meanwhile, touts numerous benefits of its end of line automation. From efficiency and cost reduction to quality assurance and flexibility, the company’s equipment delivers in a multitude of ways.
“Automated systems are less prone to errors compared to manual processes, leading to fewer defects and rework,” says Beaudoin. “This helps improve overall productivity and reduces waste in the production process. Automated systems also often come equipped with data tracking and analysis capabilities, providing valuable insights into production metrics such as throughput, downtime, and material usage. This data can be used to optimize processes, identify areas for improvement, and make informed business decisions.
“Overall, investing in LemuGroup’s End of Line Packaging Automation enables label converters to enhance productivity, quality, and competitiveness in the market, ultimately leading to improved customer satisfaction and business success,” he adds.
Prati showcased numerous automated products at Labelexpo Europe.
With a plethora of new materials out on the market, Martin Automatic has designed its equipment to seamlessly integrate with the printing and converting processes present in label printing shops.
“Automation allows operators to prepare webs more efficiently and quickly, and that allows the unwinding of webs at higher speeds and lower tensions and using of material, consistently down to the core, all stimulate decisions in favor of web automation,” says Rittmeyer. “And rewinds that accommodate non-symmetrical or non-homogeneous labels and packaging material help in the decision to include web automation from start to finish. In addition, advances in other technology, such as on-line inspection systems, are allowing more printers and converters to automate the rewinding function and reduce their off-line processes.”
Martin Automatic offers a comprehensive range of nonstop, high performance automatic splicing unwind, rewind and tension control equipment. The company produces equipment for all sectors of the label and packaging markets capable of automating any web fed process, from conventional and digital presses to narrow web and wide web coating and laminating lines.
“We help produce the material in web format that is converted to narrow web rolls that is then used by converters to produce the labels and packaging material we use with our food, beverage and consumer goods products,” says Rittmeyer. “Our commitment to reliability, operator convenience, cost efficiency, innovation, and relentless support of our customers has set the standard for automated converting equipment.”
Many converters have a requirement for off-line slitting, inspection and doctoring of rolls. For these, Martin Automatic also offers a control package to interface its rewinders with the leading on-press inspection systems. “In a typical integration, the LRD will send a signal to place a label or flag on the web,” adds Rittmeyer. “Upon an automatic roll transfer, the label will be on the outer wrap of the finished roll, where it can be scanned in an off-line operation for information and easy identification of defect points in the roll.”
Finally, Prati boasts a wide range of machines that feature automatic knife positioning, tension control, camera web guiding, laser diecutting, variable data personalization, inline inspection, automated workflows, automatic data loading and collection to provide flexibility, quick job changeovers, and high-quality finishing, enabling businesses to meet the demands of short runs, versioning, and variable data printing, among others. According to Prati, these innovations have boosted productivity for the company’s customers by 40%.
“All this leads to faster production cycles, shorter lead times, and improved overall efficiency,” concludes Prati.
Converters that L&NW talks to cite automation as one of the industry’s hottest trends – mainly out of necessity. Horror stories about labor shortages abound, but new R&D has enabled converters to do more with less. And for those facilities not lacking in manpower, those employees can be assigned to more mission-critical areas of the business.
How, exactly, does automated converting equipment simplify the life of a label printer? According to James Brennan, sales executive, A B Graphic International (ABG), automation accomplishes many tasks.
“Automation reduces the reliance on skilled operators during a job change,” says Brennan. “It simplifies the job change process for operators down to as little as scanning a QR code, which can load all data into an HMI and then automatically sets the turret, camera, slitting, back scoring, flexo initiation and more – depending on spec. By simplifying job changes, lower skilled staff are required, and converters can perform SKU changes on the fly without stopping the run or requiring operator intervention. Overall, there is reduced downtime and waste.”
“The advancements in automation technology have revolutionized the label printing industry, improving efficiency, accuracy, and productivity,” adds Chiara Prati, CEO and CSO, Prati. “One major change brought about by automation is the integration of digital printing technology into label converting equipment. Digital printing allows for faster setup times, reduced waste, and the ability to print variable data and customized labels on-demand.”
Automation is not limited to one machine or computer system, either. Much of a label printing shop’s operations can be streamlined and optimized with the newest technological capabilities.
“I am already speaking to people who are interested in automating their entire plant with control of a single computer or workstation,” explains Andre Beaudoin, director of North American sales and marketing, LemuGroup. “The impact on the industry is – and will become even more – needed and vital. As the needs of the individual converter vary, so will the level of automation required by each.”
The proof is out there, too. For example, Mercian Labels improved its finishing efficiency by 74% with an ABG Connect Digicon Series 3 compared to its previous two-step process. “ABG Connect is an automated revolution,” states Adrian Steele, managing director, Mercian Labels.”
“Converters are excited, and their expectations are increasing because automation can ease their processing and allow them to save on production costs, waste, and energy,” says Virgilio Micale, director of sales, Cartes. “Today, one of the biggest challenges for any converter is to keep operational personnel stability in the company, so automation is very helpful to have new entries trained in a short period of time.”
The Martin Automatic team touting automation at Labelexpo Europe.
For the vast majority of companies, automation is not a luxury. With staffing problems and increasing orders – with expected short turnaround times – automation is the wave of the future.
“Automation is here to stay and has now become the most needed piece of equipment in the pressroom today,” comments Beaudoin. “As our need for skilled labor has diminished, the need for end of line automation that allows for complete roll to sealed and palletized box has taken over. End of line automation has now become an accepted competitive edge in label converting.”
Converters have sought out LemuGroup to employ end of line automation to replace the missing shop workers who completed the packaging at the end of the press line to keep customers supplied with labels. A lack of staff has not led to diminished returns, thanks to the newest automated converting equipment.
“Our customers have since found that their production rates increased substantially – 30-50% – with a single operator,” says Beaudoin. “Overhead is reduced and production has shot through the roof. We have a large number of installations in the United States where this has become the standard end result. Our system is capable of working with any press or converting system currently owned.”
Sustainability is also a significant reason to automate production processes. With brands and consumers becoming ever more discerning about the environment, there is an inherent sustainability element to automated converting equipment.
“Automating the web fed process helps converters manage exposure to these increasing costs by reducing waste and increasing the meters of useable labels and packaging per unit of input – reducing waste and increasing productivity is more important now than ever before,” explains Gavin Rittmeyer, VP of sales and marketing, Martin Automatic. “Lending to this trend is the drive to produce materials with less content – thinner films take less petroleum to produce; recycled materials do not consume virgin pulp resources and linerless labels eliminate an entire web altogether, and yet adds the complexity of transporting web with exposed adhesive through the process.”
In the future, the proliferation of automated converting equipment will only continue. “As we look toward the future, the role of automation and robotics in managing material flows within factories will also become increasingly prominent,” states Haim Levit, SVP and division president, HP Industrial Print. “Accurate and real-time records of everything entering and leaving the production floor are critical, and as we look forward, we can expect the ERPs of printing companies will increasingly integrate traceability of these elements and finished products more efficiently, from the moment they leave the machines to the warehouse or the reconciliation area for swift shipping.
“With digitalization, automation, and AI-driven optimization at the forefront, the industry is poised to enter a new era of quality, versatility, productivity, sustainability, and profitability,” adds Levit.
Implementing automation
While many long-tenured employees are creatures of habit, equipment manufacturers have gone to great lengths to ensure that automation can easily be implemented – and learned – in a label printing facility.“The learning curve process is now very short since automation practically cancels out almost all variables where operational errors were the main issue,” adds Cartes’ Micale. “We believe that in the coming years the automation of processes will continue to grow exponentially.”
The engineering style also plays a role in attracting the next-generation workforce. Therefore, automation is required for tomorrow’s manufacturing employees. “We have succeeded in decreasing the learning time to get to know and start the machine, and we do this by ‘guiding’ new operators step by step on the machine, in the name of maximum safety,” notes Prati. “And since tomorrow’s operators are the kids who study and play in digital worlds today, we are adopting the concepts of gamification to make ourselves better understood.”
In addition to workforce, quality is another main driver for implementing automation in a converting business. “The ultimate objective is to achieve the buyer’s attention, which has led to products being differentiated in several ways,” adds Micale. “Equipment manufacturers have kept pace with the technological changes to develop new ways to diversify a product through the enhancement of its contained elements, often applied on labels and packaging.”
LemuGroup’s automated capabilities draw a crowd.
Martin Automatic has a very simple philosophy in place to help train new operators. “Martin focuses on equipment designs based on the 4Es: Equipment that is Easy to use, Easy to understand, Easy to maintain, and Easy to integrate – the 4Es of Martin,” states Rittmeyer. “Our commitment to KIS – Keep It Simple – and pure-form, essential engineering, allows us to minimize the time it takes to get operators proficient on our equipment.”
According to Beaudoin, LemuGroup’s customers have been quite satisfied with the returns and ease of use. In many cases, they’re placing repeat orders to further automate their plants. After investigating the new technology, they are usually sold.
“Feedback from our clients has been outstanding, and most of them are already processing second and third systems or are in the process of modifying their systems to accommodate packaging product from multiple print or converting lines,” states Beaudoin. “Once converters see the system in action, they are thrilled with the high level of efficiency and fast ROI this technology provides. Less people also means fewer insurance claims and zero wasted downtime. As one owner stated, ‘This takes us out of the HR game and back into what we do’.”
“Converters appreciate the reduction in human errors associated with manual roll changes and tension adjustments, leading to more resilient and sustainable production environments,” adds Rittmeyer. “The equipment’s user-friendly design and seamless integration with press lines have garnered praise, contributing to enhanced productivity and cost-efficiency.”
Automation allows Cartes to deliver high-quality finishing.
Current capabilities
Equipment manufacturers have worked tirelessly to add automated capabilities to their converting equipment. Much of these features differ greatly from what was commonplace some 5-10 years ago.ABG offers a wide range of automated functions for label converters. ABG Connect is the company’s automated workflow product, which sets up jobs automatically by integrating the finishing machines with an MIS or workflow product. This technology is applicable to the Digicon Series 3, DigiLite, Converter DigiLase, Vectra and SRI.
“ABG Connect is retrofittable to Digicon Series 3 and DigiLite,” says Brennan. “ABG also offers fleyeVision and Zeropoint technology for automatic, operator-free inspection setup. DigiLase, meanwhile, features automated, instant job changeovers. And DigiJet enables automated digital embellishment, with cold foil and spot varnish – coming soon.”
Plus, manufacturers will establish partnerships to further streamline a label converter’s capabilities. “In the future, we expect to see the continued expansion of machinery automation and partner integrations such as CERM,” adds ABG’s Brennan. “ABG also now has partnerships with Hybrid Software and a soon to be announced partnership with Esko.”
Cartes’ R&D has been centered around mechanical strength of machinery, precision and high production speeds. Additionally, the company has strived to provide technologies that achieve the highest quality of final products.
“Our latest technology is the Jet D-Screen (JDS), a digital screen-printing unit to create high raised embellishment,” explains Micale. “We can also add hot foil transferring, a ‘metal doming’ effect, which is completed with a fully automated concept where laser converting, auto-slitting, and rewinding are part of the configuration.”
LemuGroup, meanwhile, touts numerous benefits of its end of line automation. From efficiency and cost reduction to quality assurance and flexibility, the company’s equipment delivers in a multitude of ways.
“Automated systems are less prone to errors compared to manual processes, leading to fewer defects and rework,” says Beaudoin. “This helps improve overall productivity and reduces waste in the production process. Automated systems also often come equipped with data tracking and analysis capabilities, providing valuable insights into production metrics such as throughput, downtime, and material usage. This data can be used to optimize processes, identify areas for improvement, and make informed business decisions.
“Overall, investing in LemuGroup’s End of Line Packaging Automation enables label converters to enhance productivity, quality, and competitiveness in the market, ultimately leading to improved customer satisfaction and business success,” he adds.
Prati showcased numerous automated products at Labelexpo Europe.
With a plethora of new materials out on the market, Martin Automatic has designed its equipment to seamlessly integrate with the printing and converting processes present in label printing shops.
“Automation allows operators to prepare webs more efficiently and quickly, and that allows the unwinding of webs at higher speeds and lower tensions and using of material, consistently down to the core, all stimulate decisions in favor of web automation,” says Rittmeyer. “And rewinds that accommodate non-symmetrical or non-homogeneous labels and packaging material help in the decision to include web automation from start to finish. In addition, advances in other technology, such as on-line inspection systems, are allowing more printers and converters to automate the rewinding function and reduce their off-line processes.”
Martin Automatic offers a comprehensive range of nonstop, high performance automatic splicing unwind, rewind and tension control equipment. The company produces equipment for all sectors of the label and packaging markets capable of automating any web fed process, from conventional and digital presses to narrow web and wide web coating and laminating lines.
“We help produce the material in web format that is converted to narrow web rolls that is then used by converters to produce the labels and packaging material we use with our food, beverage and consumer goods products,” says Rittmeyer. “Our commitment to reliability, operator convenience, cost efficiency, innovation, and relentless support of our customers has set the standard for automated converting equipment.”
Many converters have a requirement for off-line slitting, inspection and doctoring of rolls. For these, Martin Automatic also offers a control package to interface its rewinders with the leading on-press inspection systems. “In a typical integration, the LRD will send a signal to place a label or flag on the web,” adds Rittmeyer. “Upon an automatic roll transfer, the label will be on the outer wrap of the finished roll, where it can be scanned in an off-line operation for information and easy identification of defect points in the roll.”
Finally, Prati boasts a wide range of machines that feature automatic knife positioning, tension control, camera web guiding, laser diecutting, variable data personalization, inline inspection, automated workflows, automatic data loading and collection to provide flexibility, quick job changeovers, and high-quality finishing, enabling businesses to meet the demands of short runs, versioning, and variable data printing, among others. According to Prati, these innovations have boosted productivity for the company’s customers by 40%.
“All this leads to faster production cycles, shorter lead times, and improved overall efficiency,” concludes Prati.
