Rewinding is a critical converting process that involves taking printed labels and winding them onto a roll. Proper rewinding equipment will promote the seamless, efficient organization of labels in a print shop. This function allows label converters to more easily get products out the door and to
their customers.

Much of the innovation in this space can directly be linked to the demands of today’s label converters. Their needs have been prioritized in the latest R&D.

“The label market demands solid, robust rewinders with simple configurations and quick job changes, without the machine limiting the customer’s production capacity,” says Andre Beaudoin, director, North American sales and marketing, LemuGroup. “In addition, this equipment can be adjusted to different user profiles, from those seeking maximum productivity to those who prioritize modular, scalable, or compact solutions that avoid oversizing the initial investment. These systems are capable of detecting defects in labels and communicating with the machine to identify and mark the affected rolls, allowing them to be automatically rejected before packaging. In this way, automation not only improves process efficiency but also ensures that only rolls that meet quality standards reach the end customer.”

The automation of rewinding has significantly improved the process as we know it. With converters struggling to find workers, the newest equipment accommodates the lack of a workforce. 

“Automated core loading, roll unloading and transfer sequences decrease physical handling and operator touches, increasing throughput and safety,” explains Angie Ostler, president, Quantum Design Inc. “Reducing production stops for roll changes is another key change in how automation has significantly reshaped rewinding.”

“Automation impacts rewinding, largely, in two main ways,” says Ralf Wirtz, managing director, A B Graphic International. “These are reduced operator input – therefore reduced chance of an error mid-job – and reduced amount of waste produced. This improves sustainability and the environmental impact of our products.”

The newest turret rewinders provide non-stop operation, enabling one roll to be wound while another is prepared. This process reduces downtime and speeds up roll changeover, resulting in higher output.  

“The integration of sensors, data collection, and predictive maintenance tools allows converters to monitor performance in real time, anticipate issues, and optimize overall equipment efficiency,” says Chiara Prati, CEO and CSO, Prati. “Automation also supports greater line integration, enabling seamless connectivity between printing, inspection, finishing, and rewinding processes.”

Automation is no longer limited to the production process, either. The end of the line has become a critical point for converters, especially with significant labor shortages. “Automating packing, palletizing, and finished product management is now key to ensuring continuity, efficiency, and operational stability,” says Beaudoin. “It has led to significant improvements in productivity, process repeatability, and reduced operating costs. For high-capacity customers, complete automation – including the end of line – has become a decisive factor in remaining competitive.”

The equipment must be suited to the unique needs of the converter. And converters are increasingly seeking more data and information from their equipment. “Key industry trends include the adoption of Industry 4.0 technologies, such as real-time data monitoring and predictive maintenance, as well as a strong focus on sustainability through lower energy consumption and reduced material waste,” notes Prati. “Modular and customizable machine platforms are also becoming increasingly important, enabling converters to scale and adapt their operations as market demands evolve. 

“Increasingly, customers also expect seamless integration with digital workflows, including connectivity with MIS systems, to manage complex jobs and variable data more efficiently,” adds Prati.

According to ABG, the rewinding equipment has been optimized to meet demand for labor issues and challenges. As it stands, many converters need the equipment to run seamlessly with fewer staff, as well as those who lack skills for the equipment.

The newest rewinding equipment can handle more volume than ever before, as well. For example, ABG’s range of SRIs are capable of multiple different actions such as slitting, inspection, or rewinding, which improves versatility and means that a higher volume of jobs can be completed. ABG’s portfolio ranges from entry level to more complex machines to meet converter needs.

Another benefit is improved roll quality, notes Ostler. “KTI’s MTR Series Turret Rewinder includes an advanced tension control dancer system and motion-based indexing that delivers more consistent roll structure and better finished roll quality. Automatic core loading helps turret rewinders efficiently handle shorter runs at higher speeds.”

Inspection plays a critical role in rewinding, too. “These systems are capable of detecting defects in labels and communicating with the machine to identify and mark the affected rolls, allowing them to be automatically rejected before packaging,” remarks Beaudoin. “In this way, automation not only improves process efficiency but also ensures that only rolls that meet quality standards reach the end customer.”

“The newest equipment is ready to identify and minimize the chance of errors, ensuring a high-quality finish thanks to its full workflow control, camera PDF verification, and line clearance and roll identification,” adds ABG’s Wirtz. “This includes SKU print data. The SRIs have ABG’s own fully automated workflow system, ABG Connect, which sorts jobs quickly and efficiently. In addition, our camera (fleyeVision) is utilized for line clearance and increased
quality checks.”

In an ideal world, converters strive for one piece of equipment to accomplish many tasks. “Converters are increasingly looking for a single machine that, with a single investment, allows them to expand their product range,” comments Beaudoin. “They are interested in being able to work with smaller diameter cores, but with the option of increasing the diameter when needed, as well as being able to work with linerless labels, all without having to change equipment: one machine, one investment.”

Critical Collaboration

Partnerships can occur with other suppliers or customers, as well. In the case of customers, many will work with their rewinding suppliers to ensure they get the tailor-made products suited for their business.

Suppliers have targeted several requests from customers when working to solve their pain points. Converters are most interested in faster changeovers, which help accommodate shorter run lengths and improve responsiveness to varied run sizes. Plus, converters are seeking consistency. 

“Consistent roll quality is key,” says Ostler. “The dancer system on the KTI MTR Series Turret Rewinder delivers a high-quality finished roll. Our automated features, such as auto-core loading, roll removal and automatic roll closure systems, all speed up the process and increase labor efficiency, too.”

As far as working with other suppliers, rewinding equipment manufacturers can ensure the converter’s workflow runs smoothly. “Collaborating with other suppliers allows us to offer a more finalized product and ensures seamless integration when installing equipment,” says Ostler. “The entire process is vetted up front and there are less surprises.” 

“Working closely with suppliers of third-party technologies integrated into our machines allows us to develop highly customized and competitive finishing solutions,” remarks Prati. “At the same time, seamless connectivity with the customer’s MIS enables a continuous data flow from the office to the machine, supporting process control, supervision, and traceability. This integrated approach improves efficiency, reduces errors, and allows converters to build flexible, high-performance finishing lines tailored to their specific production needs.”

Manufacturers of rewinding equipment also must be cognizant of substrate specifications. “Converters most commonly request advanced tension control to ensure precise and stable processing of a wide range of materials, including delicate or variable-thickness substrates,” explains Prati. “Flexibility is another critical requirement, with converters looking for equipment capable of processing multiple substrates and formats while supporting fast and efficient job changeovers.”

Meanwhile, LemuGroup seeks to offer flexible, modular solutions that are compatible with equipment from different manufacturers, as well as customized projects that analyze each specific case.

“We are committed to working closely with suppliers and companies that complement us,” states LemuGroup’s Beaudoin. “Our goal is to offer our customers high-quality equipment that meets their expectations. That is why we collaborate with companies that are experts in their respective fields, while we focus on our own know-how.  This allows us to achieve comprehensive solutions that function as a single system. In addition, this approach enables us to better understand market needs and develop practical solutions.”

Product Enhancements

ABG has developed a versatile portfolio that meets numerous converter demands. The Omega SRI3 can be configured to meet the needs of any customer. It also has fleyeVision integrated into the system to help detect errors and maximize inspection, allowing for more accurate, efficient job completion. Plus, the SRI3 is ergonomic and has the operator in mind in relation to setup. This easy-to-use unit features automation to help to minimize errors, in addition to reducing the amount of material waste produced.

“We also offer the semi-automatic turret, which, when added to the SRI3, provides precise cutting of the web between the labels and also applies the web to new cores,” explains ABG’s Wirtz. “ABG Inkjet was introduced in 2025, too. This is a modular addition to the SRI for use with ABG Braille, variable data options, DigiJet, and more.”

Meanwhile, KTI’s turret rewinding portfolio spans multiple configurations to support various converting needs. The company’s CTC product line gives Quantum Design a diverse line of turret rewinders.

The MTR Series Turret Rewinder has been designed for finished roll production with high throughout in a compact footprint. The product features motion-based control for precise indexing, tension-control dancer for quality, optional automatic core loading, and robust PLC/HMI. Plus, the MR Series Multi-Spindle Turret Rewinder is available in three or five spindle options, with an integrated festoon for zero-speed transfer suitable for lighter or film substrates. It can handle heavy rolls up to 250 pounds, roll diameters up to 24″, and web widths up to 24″. The company has also designed the KTI MT Series Matrix Turret Rewinder to mount over presses to remove matrix without press stops and complete a non-stop label line when paired with a butt splicer and turret system. 

Finally, the CTC CR4 Turret Rewinder features a compact and rugged design. Its short web path simplifies setup and adjustment, and a robust steel plate construction supports reliable long-term use. The smaller footprint allows this machine to slide into much smaller spaces than most turret rewinders on the market, says Ostler.                                                                

“This product offers short cycle times for small roll production, and it is designed with a short web path and efficient pneumatic spindle functions to optimize throughput when changeovers are frequent, thus    helping converters minimize downtime on smaller jobs,” she says.      

The CTC CR4 Turret Rewinder also has flexible roll closure systems, which include options like dedicated tail gluing and tape closure solutions. This offers converters a choice for how finished rolls are secured without waste or mess. Additionally, AC servo-drive technology is available for consistent tension and smooth winding across the roll build.  

LemuGroup’s  latest equipment options have been built on a clear strategy of modularity, scalability, and investment optimization, mainly embodied in the GTU rewinder. This is a compact and solid turret, designed to cover everything from basic rewinding needs to more demanding production configurations, allowing converters to start with simple, reliable, high-quality equipment without making an unnecessary investment in automation that they will not use from the outset.

“The GTU is based on a completely modular architecture that allows new functional modules and different levels of automation to be incorporated progressively as the customer’s production needs evolve,” states LemuGroup’s Beaudoin. “This growth can even extend to the integration of end-of-line automation solutions, all without the need to change machines or resort to other suppliers, ensuring smooth, consistent, and rapid technical integration throughout the process.”

LemuGroup also offers a modular, compact, and scalable rewinding solution that allows the initial investment to be adjusted to the customer’s actual needs, guarantees excellent finished product quality, and ensures future growth without losing value or having to redo the initial investment.

Finally, Prati’s equipment portfolio is built on high levels of automation, connectivity, and data-driven process optimization across finishing and rewinding processes. The range includes advanced inspection rewinders, non-stop glue-less turret rewinders, and fully modular finishing lines designed to meet specific production requirements.

“While current solutions leverage Industry 4.0 technologies, such as real-time monitoring and MIS integration, Prati’s new and future machines are being developed on an Industry 5.0 base,” explains Prati. “These next-generation systems are designed and manufactured according to the latest standards for sustainability, operational safety, and cybersecurity, with a strong focus on human-centric design and secure, resilient production environments.”

Martin Automatic fuels success at The Label Makers

In the six decades since The Label Makers was established in Bradford, West Yorkshire, UK, the company has always invested in the latest label equipment. Leading press manufacturing technology from Gallus, Nilpeter, MPS, Xeikon, and Durst have all been part of the development program that has produced award-winning work.

For rewinding and unwinding, The Label Makers turned to Martin Automatic. The equipment chosen and installed at the converter is a Martin Automatic MBS 04-17-40 automatic unwind butt splicer at the front end of the MPS EF 430 and a Martin LRD 05-18-31 automatic transfer rewind at the delivery end. The Martins were chosen for their design principle and robust construction that provides the all-important reliability required. 

Jamie Hyde, operations manager, The Label Makers, says, “Martin has a great reputation for keeping things simple and making them work. The functions being performed do not need sophisticated electronics, which add to the price and often reduce reliability.”

The installation in the Bradford factory was seamless but far from straightforward, with both floorspace and height restrictions. However, Martin tailored the design of its units specially to match the footprint available on the production floor. 

Chris Chappel, sales manager at Martin Automatic, says, “Although floorspace and ceiling height were initial concerns, these challenges are nothing new to us. Our portfolio of space-saving designs, including the MBS compact 90-degree turn bar model and reduced-height festoon, allows us to meet customer requirements without compromising efficiency or reliability.”

The Martin MBS butt splicer and LRD transfer rewind are well-proven across a wide range of production lines, reliably handling substrates from paper and film to laminate and board. Engineered for performance and durability, they accommodate web widths up to 660mm, roll diameters up to 1,250mm, and transfer speeds of up to 300 m/m. 

As the units were fitted onto an existing line at The Label Makers, the installation was carefully planned to ensure minimal disruption. This allows the new equipment to be integrated seamlessly while production continued smoothly.

“Because we all operate on tight margins these days, every incremental improvement in productivity yields financial rewards, and if it also improves quality, that’s an added bonus when you are specializing in embellished finishing at the top end of the market,” says Zenna Parfaniuk, managing director, The Label Makers.

Currently, The Label Makers runs both paper and filmic substrates on its presses. A typical job might be 50,000m run off on 4,000m rolls. This is where the Martin MBS really comes into its own, offering non-stop production even on the longest runs, on which Hyde estimates its saves at least 80 meters of material per roll change.

Hyde also believes that future investment will include Martin Automatic technology added to the two other MPS presses, as well as automated waste extraction to maximize efficiency.  “Martin machines are renowned for longevity. I know of instances where the same unit has been fitted to successive generations of presses, so while the ROI is short, the long-term investment return is excellent too.”