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Label Market Trends: Label Expo 2006 Highlights New Product Opportunities

By Ivars Sarkans

Label Expo, held every other year in the United States, provides an excellent view of a dynamic printing industry segment that abounds with opportunities, new technology and product innovations. The equipment, materials, supplies and systems on display reflect the current state of the label printing and the future as envisioned by machinery designers and other industry suppliers. Label Expo 2006 showed a strong but rapidly changing label industry with major shifts in product mix and intense focus on equipment productivity and versatility. A trend clearly visible in new press capabilities at the show was the gradual merging of label production into a boarder narrow-web package printing industry.

Conventional pressure-sensitive labels were no longer the ubiquitous product of the show in 2006. This suggests a perception in the industry that many traditional pressure-sensitive labels are now commodity products. The most prominently featured products in Label Expo 2006 equipment demonstrations were all film-based. This included film labels, shrink film sleeves, printed film for packaging applications and other film specialties. Clearly the “no-label' look of clear film labels is popular. The growing role of film stocks in the label industry represents a major shift to more complex products and development of higher value applications. Films require new press and finishing capabilities to cope with webs that can easily stretch, wrinkle or distort when subjected to the heat of ink dryers. The result is a surge of new opportunities for product innovators, manufacturers who can take advantage of new equipment capabilities and companies with strong marketing programs.

Label Production Trends

The gradual industry product mix shift from paper-based to film-based labels and increased use of label presses for printing folding carton board and other packaging materials are affecting production practices, choices of inks, coatings and dryer configurations. Equipment suppliers are responding to the competitive pressures experienced by label and packaging printers with machines that can run faster, wider and print better. This in turn is generating more interest in camera-based print quality and registration viewing attachments to presses and fully automatic 100% inspection systems for presses and rewinders. Several Label Expo 2006 printing and finishing exhibits included the Helios automatic inspection system from Advanced Vision Technology (AVT), the apparent leading supplier of this technology.

Computer-to-plate (CTP) systems are gaining wider acceptance in the label industry, partly due to the continued quest for flexographic printing quality that can rival offset-printed process color images. Some of the new CTP systems for digital flexo plates have additional capabilities to support hybrid presses that combine different printing processes. The Kodak Thermoflex hybrid platesetter introduced at Label Expo 2006 can image digital flexo and thermal offset plates. Esko Graphics showed the CDI Spark 2120 imager for digital flexo and letterpress plates and ablative film. Stork Printers America introduced the Helios 6010 direct laser engraving machine for flexo and letterpress plates and rotary screens. DuPont demonstrated a processing system for digital flexo plates that eliminates chemicals by use of a fabric developer combined with heat and pressure. Label Expo 2006 had numerous digital proofing systems to support the increased use of flexo CTP plates as part of the major shift in label industry prepress practices.

To accommodate printing of materials ranging from films to folding carton board, the trend in label presses is design of platform machines that can accept a mix of different print cartridges for flexo, letterpress, gravure offset and rotary screen printing. Practically all new platform presses at Label Expo 2006 had computer-controlled servomotor drive systems, and many updates of older models had a servomotor drive option. These new drives eliminate gear train problems and allow very precise control of web tension and registration adjustments. Servomotors also enable the development of many quick setup features.

Practically all label presses that can print films now also have a cold foil application option, a trend that also parallels the popularity of film-based labels and overcomes limitations of hot foil stamping on heat sensitive materials. Another significant trend is use of rotary screen units on label presses to apply a white base for printing on transparent films and applying various special coatings. Films present major challenges in drying without web distortion, and new dryer designs include chilled cylinders that carry the web through drying stations.

Laser die cutting has been demonstrated at previous shows, and the exhibits at Label Expo 2006 confirmed that the process is improving. Installations to date are limited mainly to specialized short run applications, in some cases together with a digital label press. Wider acceptance of laser die cutting is constrained by the high cost of the machines, relatively low running speeds and limitations in cutting some film materials. Typically, a laser die cutter costing approximately $350,000 is rated to run at less that 100 feet per minute, and intricate cuts may run much slower. The trend in short run applications has been towards use of much less expensive intermittent-feed die cutting units with flexible dies. These die cutters use a fixed repeat magnetic cylinder and servomotor drives to control intermittent web feeding. Only the dies are changed as needed, not the die cylinder. Cut repeat is controlled from a panel where the operator programs web feed length for all label sizes. The intermittent-feed die cutters are available for in-line installation with digital label presses or as off-line machines that may combine die cutting with coating or other auxiliary operations.

Label Presses

The machines at the center of label production systems are becoming more sophisticated in terms of print quality, web control, quick setup and range of product capabilities. Press changeovers between products in less than 10 minutes were the norm in demonstrations. Label Expo 2006 showed that both equipment suppliers and buyers now view label presses as narrow-web package printing machines, with labels just one of the capabilities. The latest models introduced at Label Expo 2006 were designed to run materials ranging from very thin unsupported films to heavy folding carton board. Mixing of flexographic, letterpress, rotary screen, gravure or offset print units on the same press is becoming a common option. Such a wide range of press capabilities is enabled by individual servomotors to drive each printing and finishing station. Computer control of these multiple servomotors allows very precise control of web tension and registration to run thin films and folding carton board on the same press. Rapidly rising prices of many films, which are derived from petroleum products, have been driving demand for thinner versions of these materials, posing greater web control challenges for label press suppliers and limiting the effectiveness of older machines.

The Comco Division of Mark Andy introduced a new press model, the C-2, as a successor to the versatile Pro Glide model line. If Label Expo was a fashion show, the C-2 would win the “best dressed model” price by a wide margin. The design of the guards and covers gives this press a futuristic and sophisticated appearance that sets it apart from all typical label presses. This servomotor-driven platform press can have a combination of flexo, letterpress gravure and rotary screen print stations, coating units, hot or cold foiling and a vast range of other options. UV dryers are mounted above the print units, against a cooled cylinder that carries the web. These types of design features address the challenges of running materials ranging from thin films to folding carton board. At Label Expo 2006, the 22” wide Comco C-2 was demonstrated running 12 micron (.0005”) film at the full rated speed of 1,000 feet per minute – and even at that speed, the press was surprisingly quiet. To minimize setup time, print cartridges pull out on built-in rails for easy access to all cylinders, print units can be pre-registered without wasting material, and registration is controlled automatically throughout the press speed range. This model is available in various web widths up to 32” for specialty and package printing applications, not just labels.

Another 1,000 feet permin. press was the FPC model introduced by Aquaflex, designed as a servomotor-drive platform press for materials ranging from films to 24 point board. While the conventional appearance of this press will not win any fashion awards, performance in demonstration runs was impressive. The Aquaflex FPC is available in 5 web widths, from 16” to 32”. This press is designed for use of plate and anilox cylinder sleeves, a relatively new technology advance on narrow-web flexo presses. A second press introduced by Aquaflex specifically for labels and tags had a combination line shaft and servomotor drive that also allows printing of unsupported films, according to the company. Typical of new label press models, the Aquaflex ELS is rated for 750 feet per minute, and is available in 10” and 13” web widths. Aquaflex has offered monochrome ink jet imaging of bar codes and other variable information on a label press for several years, and this option is available for the new ELS model with Jetrion ink jet units.

MPS Systems BV, a relatively recent participant (founded in 1996) in the label and package printing market, introduced four new servomotor-drive models with a full range of print unit and other options for labels, unsupported films and folding carton board. These presses have a unique web-driven impression cylinder with a hard rubber covering that is claimed to reduce dot gain and extend plate life. The 9 unit 22” wide UV-flexo EFP model demonstrated at Label Expo 2006 had provisions for changing an imprint plate without stopping the press. Other options included automatic register control, second-pass printing on a pre-printed web, laminating stations, temperature-controlled rollers to run films and the ability to use print sleeves in the standard flexo towers of this press.

Other major press suppliers at Label Expo 2006, including Nilpeter, Gallus and Omet, have all joined the trend to servomotor-driven platform presses and models that can produce unsupported film and folding carton board products, in addition to labels. Nilpeter showed a 10 unit 16” wide UV flexo press equipped for using print sleeves and on-line automatic 100% inspection. Their MO-3300S offset press model has been updated with servomotor drives and options for flexo or rotary screen units in any print position. Gallus demonstrated a 9 unit servomotor drive, EM-280 platform with UV flexo, hot foil and cold foil stations. Omet exhibited a 6 unit Flexy-S UV-flexo press with a separate servomotor driving each plate and impression cylinder. This press uses different diameter print sleeves to change print repeat and Omet offers a unique dual magnetic cylinder die cutting station that allows repeat changes without cylinder removal.

For short runs, Codimag and Iwasaki International Inc. displayed combination rotary/intermittent feed presses with options for offset, letterpress, rotary screen and foiling stations that can run all common print repeats without changing cylinders. Specifically for “smart” labels, Edale demonstrated the Lambda servomotor-drive flexo press in line with a Tamarack Products module for adding RFID inlays to labels. The Tamarack system removes defective inlays prior to lamination and verifies that the final label has a working chip and antenna. For off-line production of RFID labels and tags, the show had machines from Bielomatic Jagenberg Inc., Melzer, Muhlbauer and Schober USA, Inc., signalizing continued strong interest in the developing “smart” tag, label and card specialty.

Digital Printing

In the label industry, digital full-color printing remains a special short run niche process, dominated by Hewlett-Packard (HP) Indigo and Punch Graphix Americas Xeikon digital color presses. The promising demonstrations of higher speed ink jet color systems at previous printing industry shows were absent from Label Expo 2006, probably because image resolution is not yet adequate for the quality level demanded in prime labels. There is a growing number of very short run digital color printer choices for labels, ranging from desktop laser printers to thermal transfer units. Some of these small low-speed printers were demonstrated in combination with in-line or free-standing computer-controlled knife die cutters.

HP-Indigo introduced the model WS-4500 web-fed digital color press as successor to the popular WS 4050 machine. The WS-4500 can print up to 7 colors and a new font end system from Esko Graphics can support both digital and conventional flexo printing. Also new is the DigiPrime 4431 web pre-coating system, which can be an off-line unit or in-line installation with the WS-4500 digital color press. The new DigiPrime coater lowers the cost of pre-coating and is expected to replace the current Topaz coating of papers for Indigo presses. In 4-color printing, the WS-4500 has a rated speed of 52 feet per minute. The Label Expo 2006 machines were paired with intermittent feed (semi-rotary) die cutting and hot foiling finishing units, which can also have additional stations for flexo coating or cold foiling. These types of semi-rotary finishing lines from at least five suppliers are used with most of the currently installed digital color label presses.

Xeikon showed the model 330 digital color label press, which now has a white ink option for the fifth color station. The in-line semi-rotary finishing equipment included a UV varnish applicator that merges a reusable film over the printed and varnished web as it passes under the UV dryers. Contact with the film as the varnish is dried gives a smooth, glossy finish, and the film is then rewound for repeated use.

A completely new UV ink jet digital color label press was introduced by Jetrion LLC, which was a division of Flint Ink at the time of Label Expo 2006, and since then has been acquired by Electronics for Imaging (EFI). The Jetrion 4000 is a 4 color machine with Xaar print heads. It is available for 4”, 6” or 8” wide webs and has a maximum rated speed of 65 feet per minute. Recognizing the current limitations of ink jet quality, Jetrion promotes this digital color press for industrial and utility label applications.

A truly innovative use of UV ink jet technology, also using Xaar drop-on-demand print heads, was a pattern coater introduced by PAT Technology Systems, Inc. The UV coating can be applied to digitally or conventionally printed webs of labels and films for special effects, image protection or as a security feature. The coater is available for 13” or 24” wide webs and can be integrated with a semi-rotary die cutting station. A label delaminating/relaminating option is available for imaging the back of a film label as a security feature or alteration-proof code. The company also offers the digital UV pattern coater in a 14.4” x 20” sheetfed version and builds conventional off-line UV coaters.

A new digital imaging alternative to labels was demonstrated by Datalase Ltd., based on a low power CO2 laser and a special coating in the desired image are of a carton, container, package or even a label. The white coating can be applied with a flexo or rotary screen station. The laser causes a chemical reaction to create a black or grey image at a higher resolution than possible with typical ink jet marking systems. The image can be text, a bar code, date or product code or a security feature. Imaging is possible through a clear film laminate for tamper-proof or rub-proof codes and security applications. Print resolution is in the 600-1,000 dpi range and the system can print 2-3 mm high characters at the rate of 1,000 per second.

Many forms manufacturers and distributors are already participating in the label market, and this dynamic segment of printing has many new opportunities. Label Expo 2006 showed that advances in materials and production technology can lead to innovative and high value new products and applications. The latest label production equipment gives manufacturers a reach into new segments of the package printing market. The challenging aspect of all the new technology at Label Expo 2006 is that faster setup and higher speeds invariably lead to more competition, and the high cost of innovative and versatile new machines can pose a barrier to new markets, products and applications. On the other hand, for manufacturers with the financial resources and marketing skills needed to take advantage of new technologies, the high cost can be a desirable deterrent for competitors.

Companies Mentioned in the Article

All trade names, model names and trademarks mentioned in this article are the property of the respective companies. Exhibitors have been identified as listed in the Label Expo 2006 show guide.

Advanced Vision Technology, Atlanta, GA, www.avt-inc.com
Aquaflex, a branch or F.L. Smithe Machine Co, Duncansville, PA, www.aquaflex.com
Bielomatik Jagenberg, Inc., Windsor, CT, www.biel-jag.com
Codimag, Bondoufle, France, www.codimag.fr
Comco Product Division of Mark Andy Inc., Milford, OH, www.markandy.com
Datalase Ltd., Norcross GA, www.datalase.com
DuPont Company, Wilmington, DE, www.dupont.com
Edale Ltd., Romsey, England, www.edale.co.uk
Electronics for Imaging (EFI), Foster City, CA, www.efi.com
Esko Graphics, Vandalia, OH, www.esko.com
Gallus, Inc., Philadelphia, PA, www.gallus.org
Hewlett-Packard Company (HP-Indigo), Atlanta, GA, www.hp.com
Iwasaki International Inc., Osaka, Japan, www.itk-iii.co.jp
Jetrion LLC, Ypsitanti, MI, www.jetrion.com
Kodak, Rochester, NY, www.graphics.kodak.com
Mark Andy, Inc., Chesterfield, MO, www.markandy.com
Melzer Machinebau, GmbH, Schwelm, Germany, www.melzergmbh.com
MPS Systems, BV, Didam, Netherlands, www.mps4u.com
M?hlbauer, Newport News, VA, www.muhlbauer.com
Nilpeter, Cincinnati, OH, www.nilpeter.com
Omet srl, Lecco, Italy, www.omet.it
PAT Technology Systems, Inc., Vaudreuil-Dorion, Quebec, Canada, www.pattechnology.com
Punch Graphix Americas, Inc. (Xeikon), Itasca, IL, www.punchgraphix.com, www.xeikon.com
Schober USA, Inc., Cincinnati, OH, www.schoberusa.com
Stork Prints America, Inc., Charlotte, NC, www.storkprints.com
Tamarck Products, Inc., Wauconda, IL, www.tamarackproducts.com

Ivars Sarkans is president of consulting firm Sarkans & Associates of Los Angeles, California and a long time contributor to DMIA publications. He can be reached by telephone at (323) 221-7791 or by email at isarkans@sarkans.com .

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