Labelexpo Americas 2024: Finishing and converting

Since Labelexpo Americas 2022, both digital and flexo printing presses have undergone significant advancements—digital presses have surged in speed, while flexo presses have embraced greater automation and efficiency. Mirroring these developments, finishing and converting equipment has evolved to keep pace, ensuring seamless integration and enhanced production capabilities.

“We are excited we were able to demonstrate the synergies between our technologies and how they can deliver unparalleled value to our customers in today’s extremely competitive market”

One of this year’s standout innovations was the introduction of much faster die-cutting systems. These advanced systems are engineered to handle the escalating speeds of modern printing presses, ensuring that finishing processes remain equally efficient and automated. This enhancement allows flexo technology to stay competitive with digital printing, especially in the production of shorter runs.

In addition to die-cutting advancements, there have been significant strides in digital embellishment techniques. Innovations such as inkjet varnishing, various digital metalization options and laser die-cutting are contributing to more streamlined and efficient production workflows. Other notable highlights included inspection rewind units, shrink sleeve converting equipment and specialized machines for RFID label production, all underscoring the ongoing technological progress in the industry.

Innovation through collaboration

Facing rising costs and a shortage of skilled labor, converters are under immense pressure to boost productivity. In response, Martin Automatic partnered with ETI Converting, Lemu Group and Lundberg Tech to showcase an integrated production line across four stands and over one walking aisle at the convention center in Rosemont.

Unlike a mere simulation, this live production run manufactured labels for Channeled Resources, demonstrating the efficiency and cost-saving benefits of an integrated production line. The process showcased the transformation of raw materials into finished labels in a single pass, in real time.

Gavin Rittmeyer, vice president of sales and marketing at Martin Automatic, remarks: ‘It required all of us to lower our guard and put aside our native caution so that we could make the line work seamlessly. I see it as a forerunner of the way things will develop in the market going forward.’

Maxime Bayzelon, president of ETI Converting, adds: ‘We demonstrated the synergies between our technologies and how they deliver unparalleled value in today’s competitive market. This collaboration aims to set new standards for efficiency, sustainability and overall production capabilities.’

Rittmeyer emphasized the importance of understanding end-user requirements and supporting them to maximize technological benefits without risk, highlighting the unique nature of their live demonstration.

Enhancing speed and automation

A B Graphic International (ABG) presented 12 machines from its global manufacturing sites, showcasing a portfolio focused on speed and automation. Central to its display was ABG Connect, an automated workflow technology featured on the flagship Digicon Series 3. This system offers automated job changeovers, revolutionizing production processes.

The Digicon Series 3 also debuted a new semi-rotary flexo head, capable of utilizing either a sleeve system or a cylinder with fully motorized impression settings.

Mark Hyde, sales manager at ABG, highlights: ‘One major benefit of this new head is the very quick makeready, running in semi-rotary mode at 305ft/min (93m/min) and up to 590ft/min (180m/min) in rotary mode, perfectly complementing the latest HP Indigo V12 digital press.’

AstroNova, alongside its subsidiary MTEX NS, showcased the TrojanLabel T2-PRO and Atom 3 + Cutmaster. Mike Natalizia, CTO of AstroNova, confirmed that after active beta trials in early 2024, the company has already begun booking and shipping commercial units to early customers.

Cartes, an Italian manufacturer, launched the compact GE261L Star Line laser converting machine and the Gemini Series GE363WJL. This combination with Jet D-Screen offers a semi-rotary flexo and laser converting system for no-tooling operations.

Additionally, Grafisk Maskinfabrik (GM) premiered its high-speed single anvil die-cutter integrated into the DC350 finishing line, boasting a rotary die-cutting speed of 120m/min (400ft/min) in semi-rotary mode.

Matthew Gindele, vice president of sales for North America 
at GM, comments: ‘Our new die-cutter sets a new industry standard, delivering high-speed performance without the complexities and costs of traditional systems while offering maximum customization.’

Advanced finishing technologies

Grafotronic showcased four machines, including its flagship DCL2, in two configurations and two versions of the CF2. The CF2 in a HAPTIC configuration features flatbed screen printing and a hot stamping module with ultra-high stamping pressure control, enabling multi-stroke foiling and embossing.

The company also introduced Infinity, an automatic turret designed for producing a wide range of labels, including those on delicate, heat-sensitive substrates. Infinity offers numerous automatic changeover capabilities, ensuring clean label separation, automatic core positioning and finished roll ejection.

Karlville presented its post-print flexible packaging machinery for pouch production, lamination, and slitting. The compact KS-SUP-400-D pouch machine is engineered for short to medium runs, offering low power consumption, minimal waste, reduced maintenance costs and quick setup. Additionally, the Karlville Swiss Compact D Model facilitates rapid changes for standup pouches using Charter MDO PE Mono Material.

Gonderflex showcased its GFXL 3000 finisher in the dedicated FlexPack Factory area, demonstrating in-line thermal lamination, flexo printing and varnish, digital embellishment by JetFX, cold foil, cast and cure, and slitting. This multi-process platform is designed to finish rolls of digitally printed 30in wide web, alongside the R330 digital finishing machine and GFSRE-1300 compact label slitting machine.

Lemorau featured the Smart-L Premium compact machine, which includes a flexo unit in semi-rotary mode for an extra color or varnish. It also promoted the MEBR+, with its modular configuration for optional equipment like embellishment modules, and the MICR inspection slitter rewinder with variable data printing and video inspection for quality control.

Prati introduced the Digi Compact with the JetFx digital embellishment unit, combining analog and digital technologies for a wide range of materials. This machine offers an ergonomic, compact design with reduced paper passage and a focus on environmental sustainability by minimizing waste during setup.

Rhyguan Machinery presented the Top-Plus series, which connects with digital presses to enable spot varnish and semi-rotary die-cutting. Equipped with a fully automatic knife positioning system and various optional modules, the Top-Plus can achieve semi-rotary die-cutting speeds of up to 295ft/min (90m/min).

The art of embellishment

Nobelus demonstrated how tactile finishes can elevate prime labels through unsupported films and wet lamination. Featuring Karess Film for a luxuriously soft finish and FineGrit Film for a rugged, durable texture, Nobelus teamed up with Applied Molecules and GM to showcase the DC330Mini compact finishing system. This collaboration allowed visitors to experience premium haptic labels firsthand.

Angie Mohni, vice president of marketing at Nobelus, says: ‘Through our collaboration with GM, we introduced label converters to a finishing method that opens up cost-saving opportunities through higher margins and greater market opportunities.’

Dragan Nikolic, manager of business development at Nobelus, added that these special effects greatly enhance the consumer experience and help drive sales in promising markets that might otherwise be inaccessible to label converters.

“One of the major benefits of the new equipment is a very quick makeready and rotary mode speed to complement the latest HP Indigo V12 Digital Press”

JetFx promoted its digital embellishments across several machines, including the newly launched Solo Fusion, 13in wide print bar, and Solo FlexPack 30in wide, specially formulated for eBeam and UV inkjet coating for full FDA compliance.

Mike Ferrari, marketing director at JetFx, emphasized that the FDA compliance of Solo FlexPack is immensely important, especially since most flexible packaging is used in the food sector.

Embracing RFID technology

Labelexpo Americas 2024 highlighted RFID technology as a key focus area, driven by expanding mandates from major retailers like Walmart and others. The event featured dedicated areas where converters could experience the entire RFID production process, including live demonstrations of smart label production and data management.

Delta ModTech conducted RFID tag insertion demonstrations using its patented Island Transfer module and Delta Crusader platform, inserting RFID tags into pre-printed, die-cut labels.

Graphimecc Group showcased its expertise in automated machines for RFID serialization, precision converting, and mass encoding, presenting a new generation of entry-level converting and encoding machines tailored for high productivity without compromising automation or error rates.

Rosas Maschinenbau demonstrated the Leopard 300, a bidirectional tabletop rewinder with advanced RFID serialization and coding capabilities. David Rosas Wolf, managing partner at Rosas Maschinenbau, noted that with this new product, the company offers a powerful full suite for RFID label serialization and testing.

LemuGroup presented its LI220 RFID machine, capable of inserting RFID and NFC labels between the front label and the liner, equipped with a Voyantic system for real-time inspection. Tamarack Products introduced its versatile RFID inlay insertion equipment, available as standalone systems or integrated with flexo presses, designed for scalability and precision in high-volume production environments.

Highlights around the show floor

Actega promoted its low-migration inks and specialty coatings for labels and flexible packaging, announcing expanded cooperation with All4Labels Packaging Group to extend the use of Signite technology to more geographies.

Arrow Systems debuted the ArrowJet 330R M Series in the US, featuring a modular design that allows integration of various in-line technologies like priming, varnish, lamination and slitting. They also showcased the upgraded EZCut digital knife-finishing equipment with auto knife adjustment, roll-to-part options, and auto-job change features.

Ashe Converting Machinery demonstrated the Opal glueless turret rewinder with patented cut and transfer technology, including the Opal ISR full 100 percent label inspection slitter rewinder and a range of converting lines with full rotary die-cutting and wide web equipment.

Daco Solutions, in collaboration with Flexo Export, exhibited the Daco PLD-430M semi-automatic turret rewinder, featuring a 17in web, 40in unwind with roll lift, laminating station, two die-cut to register rotary die stations, auto-set slitting, and a three-spindle semi-automatic turret rewinder with roll closure.

DMS presented its latest innovations in hot stamping and foil-saving technology, including the FV-Series hot stamping system and advanced foil handling technologies.

D.P.R. Labeling showcased its Taurus system, a laser cutting and laminating machine that eliminates the need for pre-die cut labels and die tools. The Aries semi-rotary label finishing machine was also promoted, combining multiple finishing processes in a single pass with a touchscreen PC interface and flexible magnetic die plate.

EMT introduced its Rotocontrol portfolio of finishing machines, featuring integrated vision inspection, semi-automatic turrets, multiple slitting options, counting, and product detection technologies. They also promoted the Rotocontrol DT 2.0 modular hybrid digital finishing line, compatible with all major digital printing presses.

“Special effects and embellishments greatly enhance the consumer experience and help drive sales in all sorts of promising markets that might otherwise be inaccessible to label converters”

GPPE Automation Group promoted its range of roll converting and packaging products, including fully automatic thermal roll slitting, self-adhesive slitting, flexographic, and digital printing machines, serving various sectors like thermal paper, POS, ATM and logistics.

Jennerjahn featured its line of slitter rewinders designed for liner-less print and stick POS rolls, eliminating the need for traditional release liners and reducing waste and costs. Its machines cater to applications such as retail receipts, food and beverage labels, pharmacy, healthcare, logistics and hospitality.

Kampf and Atlas showcased their slitting and rewinding products, including the Unicon spindle machine, Unislit CS station machine, Kampf ConSlitter, and Atlas TitanSlitter series.

Kroenert highlighted its coating and laminating technologies for materials like paper, foil, film, cardboard and non-woven fabrics. The company promoted high-performance systems with web widths up to 3,300 mm, coating thicknesses from 100 nanometers to over 1 mm, and processing speeds up to 1,600m/min.

Mühlbauer presented an entry-level equipment package featuring the IL 30000 delam/relam unit and the PL light R2R, capable of handling multiple jobs within a single batch with a small footprint and high speeds.

Ningbo Jingwei Systemtechnik showcased its R-Cutter 
series, an all-in-one label-cutting technology concept leveraging smart systems for quick setup and seamless integration into existing workflows.

Schober exhibited high-performance finishing technologies 
for in-mold labels, folding cartons, and technical products, promoting rotary cutting, creasing, punching equipment and the RSM stacking machine.

Shandong Hoaco Automation Technology presented its motion-controlled die-cutting, web converting and packaging systems, including multi-station rotary die-cutting machines for diverse markets such as electronics, medical, cosmetics, printing, packaging and automotive.

Tectuprint showcased a wide range of finishing equipment, including die-cutters, cutters, robinators, coil elevators, punching units, perforators, stackers, rewinders, unwinders and roll lifters.

Wuhan Golden Laser highlighted its high-speed laser die-cutting machines, including the LC350, a fully digital and automated system for roll-to-roll, roll-to-sheet, and roll-to-part applications with a maximum web width of 13.7in and operating speeds up to 393ft/min (120m/min). They also featured the LC230 die-cutter for digital short-run finishing, offering zero pattern changeover time and no tooling costs, operating with web widths up to 9 inches and speeds up to 60m/min.

Zhejiang GaoBao Machinery showcased its slitting/rewinding and sheet-cutting machines for processing various materials, including paper, adhesive paper, plastic film, aluminum foil and non-woven fabrics.