The inclusion of both flexographic technologies and automated converting equipment in our April issue comes as no coincidence. Flexography, automation, and advanced converting technologies are all intertwined, boosting success for the industry’s top label converters.

Much of this product development supports converters grappling with a workforce crisis. Not only is there a lack of skilled employees, but customers are also demanding faster turnaround times. Automation allows the converter to accomplish more with less while also attracting a new generation of employees that grew up with technology.

“Automation allows you to increase productivity, reduce downtime and reach your sustainability goals by reducing waste and time,” says Omet’s Alex Bullock. “It also allows you to be more consistent with quality.”

“Automation reduces the reliance on skilled operators during a job change,” adds ABG’s James 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.”

Much like sustainability and digital printing, automation is no longer a nice-to-have option in your pressroom. A lack of staff has not led to diminished returns, thanks to the newest automated converting equipment. The results are in, too. For example, LemuGroup has noticed production rates among its customers have increased substantially – 30-50% – with a single operator. Meanwhile, Mercian Labels saw a jolt in finishing efficiency of 74% by installing an ABG Connect Digicon Series 3 compared to its previous two-step process.

Heidelberg-Gallus, meanwhile, has innovated its flexo presses with the operator in mind. The company’s servo-driven module approach features automation controls in areas like web tension, registration, and drying. This allows the operator to set up substrate media profiles where they’re subsequently stored for repeat jobs, thus reducing make-ready time and waste while improving job consistency within the run and on repeat jobs.

User-friendly is the name of the game. While flexography was once thought of as a form of art, with a press operator doubling as a craftsman, automation has simplified the process. Manufacturers are doing their part to bring the newest flexo presses to a place where employees of the future, many of whom have grown up in a digital world, will be enticed to enter this space. If they cannot be lured to the industry, then presses and converting equipment must be capable of accomplishing the same tasks – with fewer operators. The same holds true for the newest converting equipment.

These technologies will all be on display at various open houses slated for this spring and summer, as well as Labelexpo Americas and PRINTING United, both scheduled for September 10-12, 2024, in Rosemont, IL, and Las Vegas, NV, respectively.

Greg Hrinya, Editor
[email protected]