Labelexpo Americas 2024: Workflow and inspection

Developments in workflow and inspection technology at Labelexpo Americas 2024 showed leading vendors responding to converters’ desire to maximize productivity, increase efficiency and reduce waste. While AI has in recent years been integrated into inspection systems to optimize defect detection, it is increasingly being further deployed in other areas of workflow, as evidenced by Cerm’s new AI-based Scheduling Optimizer. 

Consolidation among workflow companies – as outlined in these pages following Labelexpo Europe last year – continues, with Label Traxx acquired by Amtech Software earlier this year, following its acquisition of partner companies Batched and Siteline in 2023. Increasingly, label converters can turn to a single supplier for a multitude of workflow solutions.

L&L rounds up what was on display at Labelexpo Americas 2024.

Baldwin Vision Systems, on the stand of parent company BW Converting, demonstrated its range of inspection, LED curing and corona treatment technologies for the narrow web flexo market. 

Baldwin’s new PQV 4.0 process-optimization tool has been developed to enhance the inspection process, reducing the risk of human error and improving accuracy. PQV 4.0 can detect errors and faults with micrometer precision and provides a detailed report for correcting mistakes. 

At Labelexpo, Baldwin presented the Corona SlimLine surface treatment, which bonds ink onto plastics, making it suitable for label printing and narrow web applications. The compact system provides power, electrode settings, and comfortable and ergonomic handling, operation and cleaning.

BST introduced SmartData QLink, a system enabling integration into existing workflows to automate label printing, from pre-press to finishing, packaging and dispatch.
In the pre-press workflow, job data is generated via interfaces to common ERP and MIS systems and sent to the print department via the customer network. Connecting to popular software packages such as Esko and Hybrid enables smooth integration into existing workflows. 

Vendors are responding to converters’ desire to maximize productivity, increase efficiency and reduce waste

The pre-press workflow includes defining the artwork in the layout program, whereby inspection zones are already defined, e.g., for variable barcodes or alphanumeric sequences. The pre-press software then automatically generates the step-and-repeat.

During the printing process, TubeScan monitors the results, including variable data and image finishing inspection. Reference images can be derived from the PDF or validated by comparison with the first printed repeat. 

With SmartData QLink, the roll log can be edited during printing. The ‘good’ count is displayed in real-time – per roll or cumulated over the entire job.

The new BST Dynamic Job Change technology enables a job change without stopping the machine. The TubeScan system automatically recognizes the new job and retrieves the corresponding master in real time for comparison during the inspection, saving time and reducing waste.  

The QLink data from the printing process is used for further processing to rectify defects. In the post-press area, SmartData QLink provides the error logs via the lead-out barcode. Based on the roll map of the job, stored defects are processed efficiently, with the TubeScan placement function controlling the converting machine and enabling precise positioning of the faulty repeat. The rewinder can also be controlled with QLink Rewinder for automatic defect positioning. 

Cerm unveiled its new AI-based Scheduling Optimizer. Powered by advanced AI algorithms, the Scheduling Optimizer streamlines long-term planning while allowing planners to focus on short-term adjustments tailored to specific production needs. This innovation is designed to improve efficiency, reduce costs and prepare businesses for the future of production management.

During live demonstrations, attendees saw how the tool simplifies production planning by handling long-term scheduling and allowing planners to focus on a ‘frozen window’ of short-term tasks adjusted to pre-defined parameters. The AI capabilities of the Scheduling Optimizer enable it to adapt to a wide range of production scenarios.
Also new was an AI-powered support assistant, Lumi, which offers Cerm MIS users immediate, 24/7, intelligent assistance. Lumi’s capabilities promise to reduce downtime and improve operational efficiency by delivering precise, on-demand assistance that helps users maximize the potential of Cerm MIS.

According to marketing manager Sebastiaan Hermans, the project was born from Cerm’s own need to boost efficiency during the onboarding process of new team members and will ‘transform how our clients experience support.’

Decosystem showcased Sentinel, an inspection technology developed for the label industry in different versions: silver, palladium, gold and platinum. Sentinel includes 100 percent print inspection control, color control, 2D and 3D code reading and grading and variable data verification. The optional Sentinel Workflow enables linking the printing machine and rewinder flow to save waste and keep production under control.

eProductivity Software showed the rearchitected Radius ERP and ePS Packaging Suite, featuring intuitive workflows, advanced integrations and automation with technology partners like HP Indigo PrintOS and Esko Automation Engine. Key highlights include full digital workflow automation and real-time visibility and traceability for packaging converters.

Esko showcased innovations in cloud technology, estimating software and in-line inspection hardware. The new Esko S2 platform is a cloud-based platform based on cloud computing, data sharing and AI. Esko’s marketing director Jan De Roeck says: ‘All Esko applications connect to the new platform, giving all stakeholders in the value chain 24/7 real-time access to live data and identical resources, wherever in the world they reside. Moreover, Esko S2 is an open platform supporting connectivity with partners.’

Also on show was Esko’s new varnish inspection module for the Esko AVT Helios system, which facilitates viewing and inspection of varnish and coating on various substrates simultaneously with print inspection. 

EyeC showed live demonstrations of the new EyeC ProofRunner options for AI-based defect classification and the improved EyeC Proofiler DT series. The company’s newest in-line inspection system – the EyeC ProofRunner Highlight – was shown on a Prati rewinder. 

The in-line inspection system offers 100 percent print inspection for labels and flexible packaging with web widths of up to 1,700mm. New options for the ProofRunner line include AI-based defect classification. With precise defect classification based on the image content, relevant defects can be identified more clearly and brought to the operator’s attention. 

The EyeC Proofiler 1200 DT, for quality control of large-format print samples, featured improved speed, handling and ease of maintenance. There were also demonstrations of EyeC Proofiler Graphic, an artwork proofreading software for automatically comparing print-ready or step-and-repeat files with approved artwork. 

EyeC also showed its inspection technology for RFID labels. The software conducts precise measurements and comparisons to maintain quality control by identifying deviations from the original PDF. 

Formic promoted its robotics-as-a-service product to help factories start automating. The company delivers customized robot systems from leading vendors at hourly rates with no upfront investments, guaranteed uptime, and full service, including everything from planning and deployment to maintenance and upgrades. 

GlobalVision featured products for proofreading, quality assurance and requirements for regulated industries with capabilities including braille height inspection, print inspection, text inspection, barcode inspection, cloud PDF and proof inspection, large-format scanners for full press sheet inspection, and counting systems for inserts, cartons and vials. 

GMG Americas highlighted four technologies at the show. ColorFarm, distributed by GMG, is a production cockpit for GMG technologies that streamlines processes, integrates preflighting, and centralizes information management between GMG software. With its easy job quoting and production control, ColorFarm adds cost-saving potential to industrial digital printing.

Also on show was GMG ColorProof, designed specifically for HP Indigo. It delivers predictability and cost-effective proofs, freeing up press capacity and enabling integration of proofing without disrupting press schedules.

The company also promoted its Proofing Calculator Tool, which demonstrates cost savings possible with GMG ColorProof for HP Indigo; and GMG ColorPlugin for Adobe Illustrator, offering a vector conversion. 

GSE Dispensing, on the stand of its North American distributor UPrint Technologies, introduced the redesign of its software program, GSE Advanced reporting. The new version automatically sends reports from the dispensing machine, giving businesses deeper insights into ink consumption. 

In the fourth quarter of 2024, GSE will introduce a service to upgrade its global installed base of Colorsat ink dispensing systems and Ink manager software to Windows 11. The initiative will ensure GSE’s customers benefit from the enhanced security and performance of the latest Windows operating system. 

GTI Graphic Technology presented its new D50 LED product portfolio, including desktop systems, floor stand models, large format viewing systems and press console viewing stations. The LED lamps used in these products have a CRI that is greater than 98, are environmentally friendly, offer compliance to ISO 3664:2009 for 7,500 hours of use, are EU RoHS compliant, require no warm-up time, and are available in lengths of 24in, 36in, 48in, and 60in.

Hybrid Software showcased its product portfolio, including the new PackZ10, CloudFlow, ColorLogic’s color management software, SmartDFE and iC3D. Hybrid PackZ10 is the latest version of the company’s all-in-one PDF editor. It adds new capabilities for both digital and conventional printing, including enhanced 3D visualization and ray tracing for shrink sleeves and die-formed metal cans. The product utilizes a tight integration of two Hybrid Software products, iC3D and Capture 3D. PackZ10 supports the direct interface to the new LabelStream LS2000 digital press.

Hybrid Software’s auto layout and step-and-repeat technology for roll-fed digital labels and stack offset printers, Packzimizer, includes new features to manage short print runs and smaller quantities. It analyzes order data to optimize the layout and repetitions of labels on a roll based on quantity, offering maximum substrate usage and press uptime.

Consolidation among workflow companies continues, with Label Traxx acquired by Amtech Software earlier this year

Hybrid CloudFlow is a configurable enterprise production workflow system that automates pre-press tasks. MyCloudFlow is a 100 percent cloud-based SaaS technology running in a dedicated Amazon Web Services (AWS) cluster and supported by Hybrid’s IT team, with strong data protection and immutable backups.

CloudFlow’s ProofScope tool for artwork viewing and approval now includes a 3D approval system based on iC3D technology. Users can visualize product labels as well as embellishments like glitter and varnishes applied directly to three-dimensional shapes, including cartons and bottles. 

ColorSpace offers optimized color matching for digital and conventional printing to all users of PackZ and CloudFlow. It supports different color spaces, from process color and extended gamut printing to specific brand color inks. It offers an automatic selection of the best ink configuration for each job on a given printing press based on the slightest deviation from the desired spectral color (∆E), with reporting to MIS/ERP for accurate quoting.

SmartDFE is an intelligent digital front end (DFE) targeted at high-speed, single-pass digital presses printing variable data. It is built upon Harlequin Direct, providing rasterization and inkjet drop generation. It offers independence from third-party core RIP technologies, relying on Hybrid’s own Harlequin Core as well as workflow technology based on CloudFlow, and color management from ColorLogic. SmartDFE is used to power several digital label presses that are displayed at Labelexpo, although it is often marketed and sold under Hybrid Software OEM customers’ brand names.

Infigo demonstrated its web-to-label platform, which can easily integrate with other software and hardware to create a seamless workflow. New Connect modules allow integration with Label Traxx and Cerm MIS systems, while the Infigo Label Factory allows the user to build their own web-to-label business by creating a storefront in minutes.

Infinity ID promoted its integrated IOT software, developed to optimize and simplify the value chain’s operations and processes. Based on RFID technology, it offers modular products for every sector that connect every item and communicate with management systems.

Label Traxx exhibited at Labelexpo Americas for the first time as part of Amtech Software following its acquisition earlier this year. The combined company provides software to more than 750 customers and 1,200 manufacturing sites across the globe. At the show, the company demonstrated new product enhancements for Label Traxx, including updates to its core ERP as well as Batched and Siteline. New developments include the Lead Time Manager and Automatic Stock Planning tool for Batched, Automated Order Entry for Siteline, and multi-site Enterprise Edition of Label Traxx. 

MicroDynamics carried out live demos of the Veritas and MicroScan3 anilox inspection systems. With +/- 1 percent repeatability and scans in less than 10 seconds, users can inspect a wide variety of engraving depths, shapes and sizes, quickly and accurately. Also on show was a newly released wide field mode which doubles the field of view to inspect a wider range of rolls without the risks or downtime of lens changes. 

OneVision Software showcased its Label Automation Suite, which combines production planning with print file optimization. Digital printers can control and monitor label production with all steps mapped transparently in the software as a digital job bag. The modular structure of the software enables individual configurations tailored to specific requirements. 

OneVision is a technology partner for Canon’s new LabelStream LS2000 inkjet press, and the company focused on how users of the press can benefit from its process automation and end-to-end workflow. 

Priber promoted the SQ Label software suite for efficient and reliable barcode and label printing. It features specialized tools for cable and wire marking, double-sided printing and an integrated product catalog.

Re promoted ReVision Net, an integrated web viewing and control system. From a single control point, with up to two touch displays, operators have access to any number of ultra-compact, high-quality cameras. The system offers a large field of view and captures still details with 16 times zoom even at high web speeds. 

Seradex demonstrated its ERP manufacturing software, which includes MIS systems for label and package printing. The company has created an ERP program that automates leads, opportunities, quotes, orders, sales, manufacturing, scheduling, purchasing, inventory and financials into one application, eliminating information silos. 

Among the options offered by Seradex’s software, Powerful Product Configuration allows the generation of accurate estimates for any job, CRM tools allow sales reps to manage their pipeline and repeat orders, Shop Floor tools enable scheduling and management of personnel, machines, inks and substrates, and Workflow tools manage artwork, dies, production and purchasing.

TR Electronics demonstrated measuring and positioning technologies specifically designed to optimize label manufacturing operations. They ensure precise label detection and positioning, even at high belt speeds. TR Electronics products are calibrated for a wide range of label materials, including paper, metallic, transparent, and both thin and thick labels. 

Troika Systems presented its AniCAM HD Plus and focused its Labelexpo presence on topics such as 3D anilox measurement, the importance of precision roll, cylinder and plate inspection, as well as sustainability goals. Troika’s 3D scanning microscopes measure anilox and gravure cylinder volumes, as well as flexo plate dot, and by recording the data into the inventory management software, enables improvements of internal processes.  

Canada-based Ultimate Tech, making its Labelexpo Americas debut, launched a fully automated and optimized label production software for Canon’s LabelStream LS2000 inkjet label press, which was unveiled at the show and will be available next year.

Unilux featured the new UniPrint monitoring system, developed in partnership with GlobalVision, which gives operators the ability to correct defects through touch-screen controls and provides access to features like split-screen and programmable web positions. 

High-definition images captured by UniPrint are transferred to GlobalVision press proofing software for analysis on-demand. Operators are alerted of changes in quality in real-time and empowered to make corrections before the run is complete. 

UPrint Technologies launched Strobox, a developed by award-winning AI specialist NoLix. The device automates the comparison of an original PDF design with the printed output, ensuring quality control. It uses an advanced AI engine capable of non-boundary self-learning, which means the system continuously improves and adapts without predefined limits. This allows the technology to detect defects in 15 different classes, ranging from color inconsistencies and mis-registration to subtle print anomalies that might otherwise go unnoticed.

The system’s ability to learn and evolve with each print run ensures that defect detection becomes increasingly precise and reliable. ‘The Strobox represents a significant leap forward in quality assurance,’ said Edward Scheppink, CEO of UPrint Technologies. 

Voyantic showed test and quality inspection systems for high-speed Rain RFID and NFC label converting lines and processing machines. It demonstrated the Voyantic Tagsurance 3, which can ensure the quality and performance of every RFID label on the production line while giving real-time visibility into the machine operation. The modular and scalable system is easy to integrate into a wide range of machines.

X-Rite showed its latest color measurement, color specification, and quality control technology, including the eXact 2 handheld spectrophotometer with the ability to measure color across various substrates, including flexible film and paper while also verifying customer standards.