How to optimize and increase label production efficiency

Production process optimization, cost reduction, and increased efficiency are key challenges facing label printers in response to current market trends, and were the main topics discussed at the recent meeting organized by Esko and Mark Andy.  

The special Esko – Mark Andy Innovation Day, devoted to European label printers and converters, took place at the Mark Andy Technology Center in Warsaw on March 5th.  In addition to technology presentations from Esko attendees had the opportunity to take part in the live print demonstrations of Mark Andy presses.  These included the flexo Evolution Series E5 and UV inkjet hybrid, the Digital Series HD HighSpeed 1200.  Labels printed on both presses utilized advanced software solutions created by Esko, including Equinox, a tool dedicated to label and packaging production.

“The event opened our series of meetings scheduled in the Warsaw-based Technology Center for this year.  Some are organized in cooperation with our technology partners,” said Lena Chmielewska-Bontron, European Marketing Manager Mark Andy.  “This time we partnered with Esko, which offers a wide range of advanced hardware and software solutions used by our mutual customers.  The meeting attracted many attendees from Poland, Turkey, Croatia, Czech Republic and other countries.  For us, it was a great opportunity to showcase the new presses in Mark Andy’s portfolio, including the fastest UV inkjet hybrid press on the market dedicated to label production, Digital Series HD HighSpeed 1200.”  The international guests were welcomed by Mariusz Geras, Sales Manager Esko, Lukasz Chruslinski and Antony Cotton, European Sales Managers Mark Andy.  

Market trends and technological innovations

The first speaker was Jan De Roeck, Marketing Director Esko, who highlighted the dynamic global changes and uncertainty affecting both businesses and consumers.  He cited research results that outlined major business risks, the degree of preparedness for external crises, as well as preventative strategies implemented by companies.  He emphasized the importance of digital transformation in the label production market, addressing issues such as shorter print runs and faster delivery time pressures.  He identified key trends and technologies including automation, AI/machine learning, and cloud computing, that will have significant impacts on the label and packaging industries.   Mr De Roeck also illustrated the value chain specifically for packaging and label makers, pointing out the role of Esko.  As he underlined, Esko solutions are used in the production process of 9 out of 10 consumer packaging jobs. Some of these were presented in subsequent presentations and in context of their application in label production as demonstrated on the Mark Andy presses.

‘Revolution in prepress with Esko: From concept to print’

This was the title of the presentation given by Sam Coussens, Application Sales Manager at Esko.  He showed a complete workflow of a sample job file, from submission to final print, based on the Esko Automation Engine server.  He covered successive stages of job processing: prepress, file approval, platemaking and printing.  As he emphasized, over 3,000 licenses of the Esko Automation Engine are already being used worldwide, helping companies to reduce errors by up to 80%, increasing efficiency and workflow, and achieving time and financial savings.  Mr Coussens talked about selected workflow modules: Equinox – designed for job preflight; ArtPro+ – dedicated to variable data printing (VDP); and quality control tools.  He highlighted the importance of cloud-based job approval, remotely accessed by all process participants.

Innovations in Platemaking and Screening

The final Esko presentation was given by Nils Otto, Solution Architect for Color & Print.  He presented Esko solutions for flexo platemaking and screening processes.  He showcased optimized workflow for file preparation process, designed to bring measurable financial and environmental benefits.  He also highlighted Esko’s flexo platemaking systems from numerous implementations worldwide.  Finally, he spoke about standardization and calibration processes using the Esko Print Color Wizard tool.  When combined with the Equinox module, it creates a complete solution from press calibration to verification of final print.  This offers cost savings while reducing the negative environmental impact of the print production process.

Mark Andy Presses Demo

After the theory came the practical, with attendees taking part in a ‘live’ demonstration of two of the narrow-web printing presses installed at the Mark Andy Technology Center in Warsaw.  The demonstrations were led by Lukasz Chrusliński and Antony Cotton, European Sales Managers at Mark Andy. 

The hybrid Digital Series HD HighSpeed 1200 press attracted special interest from the event’s guests, owing to its recent global debut.  Described by Mark Andy as the world’s fastest UV inkjet narrow web press dedicated to label production, it operates at twice the speed of its predecessor, the Digital Series HD model, which has been a sales success story for Mark Andy in many countries.  It addresses the current market trends and customer requirements, as indicated in Esko’s earlier presentation: reduction in print run lengths; increasing demand for versioning/VDP; and a growing need to update or reprint previous jobs after necessary modifications.
Mark Andy is currently the market leader in sales of narrow web hybrid presses for label and package printing.  “Moreover, our flagship models in this segment, the Digital Series HD and recently introduced Digital Series HD HighSpeed 1200, were developed entirely in-house. This means that our customers receive a complete end-to-end solution,  including DFE software, from a single source.  The package is assisted by a comprehensive Mark Andy 360 Support service care program, “ stated Antony Cotton.

The second demo featured the well-proven Evolution Series E5 flexo press, offering production speeds up to 230 m/min.  As a scalable solution, it can be expanded and upgraded as user needs grow.  Evolution Series E5 is available in 330mm and 430 mm web widths and its application range includes labels, shrink sleeves, and IML.  “This highly versatile press aligns perfectly with current market trends and flexographic applications,” said Mr Cotton.  “Its versatility is evidenced by the different types of work it produces, from specialized cosmetic tubes using unique technology to high-volume self-adhesive labels or shrink sleeves.  Its range of applications can extend even further, depending on user specialization and target markets.”

Q&A Session
The event concluded with a Q&A session featuring representatives from Esko and Mark Andy. The questions covered technical aspects of the solutions presented as well as general topics including the current state of the market and the upcoming Labelexpo Europe trade fair, being held for the first time in Barcelona. 

“We’d like to thank all customers who participated in the Esko – Mark Andy Innovation Day and hope they gained valuable theoretical and practical knowledge.  Our Technology Center was designed as the place of learning, inspiration, experience exchange, competence building, and knowledge sharing.  In a few weeks’ time, we will be hosting students and pupils from printing colleges and high schools, and in June we are planning an Open House for customers from all over Europe.  We hope that all these events, scheduled for the first half of the year, will be a great prelude to the forthcoming Labelexpo Europe in September,” concluded Lena Chmielewska-Bontron.