Agile, flexible production floors, populated by presses optimized for full modularity, affording seamless integration between print processes.
Some say, “It’s a dream!”; others, “It’s reality!”
Most all staunchly advocate “future-proof production.” Why? The obvious answers: “Maximize uptime!” “Minimize waste!” But, when it comes to narrow web presses, a plethora of choices exists—Flexography? Digital? Hybrid? Analog or conventional?
As Dean Haertel, business director, oneLABEL Portfolio at BOBST likes to say, “One size does not fit all.” Elaborating on the point, he states, “Label production requires a blended reality. Production floor optimization is best achieved through technology diversification—inkjet, toner, flexography, hybrid.”
All photos courtesy of BOBST
Given today’s reliance on, and proliferation of, intense graphics and vibrant colors; coupled with ever-increasing calls for connectivity, digitization, automation and sustainability; he maintains, “Fleets of the same press are not sufficient for new customer demands. What worked five, even 10 years ago, is no longer a viable solution.”
Single-Pass Success
Many press manufacturers and the converters they service and support share that common vision. They operate in an environment of supply unpredictability, low-touch economy, price erosion and zero-fault packaging. All are responsible for driving change. Adaptability is critical. Modularity has become the strategic tool in a printer’s repertoire, fostering the ability to respond to ever-shifting expectations at the push of a button.
“Developments in label production are moving at breakneck pace. Brand owners are looking for converters that have the ability to deliver faster, better and at more competitive prices,” explains Patrick Graber, strategic marketing manager for BOBST. He notes that his company, like so many other manufacturers, is now, “leveraging proven flexo experience and recent innovative inkjet developments.”
Specifically pointing to the example of BOBST enhancing its All-in-One, All-Inline portfolio with the new DIGITAL MASTER 340 and DIGITAL MASTER 510, Graber proclaims, “Both are designed to change the way label production is set up.”
“Agile, flexible production floors, populated by presses optimized for full modularity, affording seamless integration between print processes. Some say, ‘It’s a dream!’; others, ‘It’s reality!'”
What’s behind the move? In addition to the desire to print, embellish and convert in a single pass, Graber decrees, “We want to solve our customers’ challenges as they try to overcome the lack of a skilled workforce, while moving to industrial productivity and longer run lengths with digital equipment; and to bring more versatility to the production floor.”
Market Share & Modularity
Both he and Haertel are cognizant of statistics: analog presses controlled 77 percent of market share in 2014, as compared to digital’s 23 percent. By close of 2024, however, that will evolve to analog at 67 percent and digital at 33 percent. They, like many others, now endorse a fully digitalized and automated production line.
“Based on a fully modular and upgradeable architecture, customers can build their own press and adapt it to customer demands as they evolve,” Graber points out. BOBST’s latest introductions are available in 13.5-in. and 20-in. print widths. Like the MASTER DM5 (a flexographic press), they offer printing, embellishment and cutting in a single pass, with seamless native integration between the UV inkjet digital engine and the flexographic and converting modules.
Running at up to 328 fpm, in four or six colors, plus optional digital white, these presses bridge the gap between traditional digital and flexographic machines. The lineup stands for flexibility, fast turnaround, and inline end-to-end label production, with exceptional quality and productivity in increasing run lengths. The modular architecture allows customers to configure the exact machine they need—from a digital-only version to highly customized configuration—integrating all modules available in inline flexography.
“Customers can adapt the machine over time to changing application needs and new market trends,” notes Graber. “And when new technologies for these platforms are released, they can be retrofitted on site, adding even more value and protecting the investment.”
Flexographic modules can be included for priming demanding substrates, high-ink coverage jobs for long printruns to save on digital ink, applications with high white coverage, or for printing Pantone colors. Available embellishment features include varnishing, tactile and holographic effects, cold foil glue applied, UV lamination and security printing. For end-to-end label production, fully automated semi-rotary die cutting or rotary die cutting are ready for integration.
Each print, embellishment and finishing module is digitally automated for exceptionally high uptime, low waste and outstanding repeatability, regardless of the operator’s skills. Quality control can be guaranteed by the inclusion of 100 percent print inspection systems. Additionally, 39-in. jumbo unwinders and rewinders, with automated roll-lifting system, reduce the number of roll changes, saving time and effort. A single user-friendly interface controls the whole machine, which can be connected to the cloud and is open for MIS integration.
“The DIGITAL MASTER series leverages the principle of ONE: ONE press for all label jobs, ONE workflow unifying all the elements, ONE operator running the press, ONE supplier developing all the technologies and ONE point of service for both conventional and digital parts,” concludes Graber.