This begs the question, where does it leave the other big Düsseldorf show, Interpack, due to open in May of this year? The inevitable overlap between the two shows will probably not benefit either. It could, however, just possibly benefit another slightly smaller show, scheduled for October 2027, which aims to bring together all the wonderful things you can do with labels and printed packaging (no prizes for guessing which show). Or of course, the pendulum could swing the other way.

FINAT ventures forth

The springtime is what prompts many managers to find new ways to look at their future, and the European label association FINAT is no exception. The association reckons that the future for the label industry can be reduced to three things: putting sustainability and recycling into practice, working together with end users to make better recycling systems, and using traceability and AI to improve productivity. Not surprisingly, FINAT will continue to work closely with LOUPE/Labelexpo.

In estimating the industry’s growth in Europe, FINAT is cautious: “The market is more stable entering 2026, but growth is modest and uneven, and uncertainty remains the baseline.”

More on security labels

Security labels for garments have been around for a while but are not always effective against dishonest customers who buy high-fashion apparel, wear it once or twice, and then return it for a refund. This phenomenon of “wardrobing” is becoming one of the biggest challenges in the fashion retail sector, and it costs the industry millions each year. 

On platforms such as Instagram and TikTok, dubious users share how they “borrow” outfits for events and then return them. The label developed by Austria’s Securikett is meant to nip this practice in the bud: visibly attached to the garment, the label can be removed cleanly and without leaving any residue. Trying to stick it back on again, says Securikett, is impossible, so returns are blatantly obvious. 

“Not the biggest, just the best” says Desmedt

Currently employing 45 and generating sales of around € 15m ($17m) a year, Desmedt is far from being Europe’s biggest label converter, nor even leader in its home country of Belgium. But it has just recently invested in a Mark Andy hybrid line: the Digital Pro MAX. 

The D-Pro MAX is the latest version of Mark Andy’s toner-based digital engine mounted on a Pro series flexo platform that provides many converting options. To complement its small overall footprint, a Martin Automatic MBSC unwind butt splice was installed. According to Desmedt’s Henri Köhler, a man not given to understatements, “When the current program is completed, ours will be the most highly automated narrow web production facility in the world.”

Paragon goes it alone

European packaging manufacturer Coveris is set to sell its paper and labels business to US investment fund Kingswood Capital Management. The transaction, announced earlier this year, reduces the group’s industrial scope to €900 million (call it a billion) in revenue and gives autonomy to Paragon Print and Packaging. 

Following the sale, which is expected to take place in the first quarter of 2026, the paper business will operate as an independent entity under its former name: Paragon Print and Packaging. The company was one of five businesses acquired by Sun Capital in 2013 to form Exopack Holdings, which became Coveris that same year. For its part, Paragon will post revenues of $312 million and employ 1,400 people.

Spare-time activities

Let’s face it, most of the big names in the label business don’t excel at much outside their business, except maybe playing golf. Happily, there are a few exceptions. Some readers may remember how the CEO of A B Graphic crossed the Atlantic in a small yacht. One of the very early creators of a successful label magazine, now in retirement, is a prolific writer of history books. Then there’s Andrea Vimercati: he’s the boss of Pilot Italia, one of Italy’s leading label converters. When he’s not running the business, he goes off and runs marathons, and what’s more he does it rather well. Not quite in the same league, your correspondent’s only claim to fame in the sporting field is to have crossed the English Channel several times in a small inflatable dinghy – and in case you jump to conclusions, no he was not ferrying illegal migrants.

And while digital and hybrid printing have made considerable headlines, especially in magazines like ours, flexo still accounts for the vast majority of pressure sensitive label production. That will continue to be the case for some time, too.

The concept of selling labels is more about promoting this great industry than landing a new account. And the ideology goes beyond flexo. Most major conferences and trade shows with educational sessions will focus some portion of their content on the workforce challenges present in our industry. Manufacturing as a whole has been hit, which is why automation and artificial intelligence also receive significant stage time at prominent industry events. But no matter how automated the process becomes, label converters will still require talented employees to fuel their operations. Even in the case of AI, someone will need to deliver the prompts to ascertain the benefits of the technology.

Technology or not – this industry has a lot to offer the next-generation workforce. With many schools offering yearly tuitions north of $70,000 and even $80,000 – and up – label manufacturing looks pretty attractive. As it should. This is an industry not going away any time soon. Even as prominent label converter Blue Label Packaging Company touts its direct-to-can printing, the technology is seen as “an extension of the company’s label and shrink sleeve offerings.” Ultimately, society cannot go without packaging in some shape or form. There will always be a need. 

Therefore, the industry must do a better job promoting itself. For example, Sttark, this month’s Narrow Web Profile on page 32, works with a local trade school, offers scholarships, and even touts an internship program.

“The scholarships we offer are an opportunity to help students,” states Kevin MacDonald, CEO, Sttark. “We believe long term there’s a benefit to that, and hopefully we can help some students out every year.”

Beyond hiring, however, is retention. Any company can find someone to walk through the door. How do we get them to stay and become a part of the culture? That is where business owners must think about their work environment as more than just a printing business. The newest technology will bring in a candidate. Creating the right workplace atmosphere will keep them here. And our industry depends on it.

Greg Hrinya, Editor
ghrinya@rodmanmedia.com

Capital for the acquisitions comes from outside investors in the private equity funds the firms establish and manage, usually supplemented by bank debt. PE firms shoot to return a 6x multiple to their investors of their own committed capital, excluding debt.

An acquisition by a private equity firm can make a company more competitive or saddle it with unsustainable debt, depending on the private equity firm’s skills and objectives. 

Some of the larger PE firms that are active in the label industry include: 

• Morgan Stanley Capital Partners: AWT Labels & Packaging
• Genstar: Brook + Whittle
• Clayton, Dubilier & Rice: Fort Dearborn and MCC
• Harvest Partners: Fortis Solutions Group
• Heartwood Partners: Outlook Group and All-American Label
• Wynnchurch Capital: MS2 Group (nee Iconex Labels)
• Sole Source Capital: I.D. Images et. al.
• River Associates: ID Label
• AEA Investors: Inovar Packaging Group
• Mason Wells: KDV Label and Industrial Labels Holdings
• LongueVue Capital: Traco Packaging
• Incline Equity Partners: NovaVision and PrimeSource
• Ares Management Corporation: Resource Label Group

I think you get the idea. This is just a sampling, as there are too many others to include in this column. One of the best disciplines that a public company already has or a PE firm brings to the table is financial skills. Many privately-owned companies simply do not keep their financials in order and are not being properly reported by their CPA firm.

There was an entire M&A Corner column written by yours truly about this topic in a previous issue. If you would like a copy of it, simply send me an email and I will forward it to you. Also, public company shareholders and PE firms like their investments to make money, so you can be sure that if a label company (competitor) is either publicly-traded or PE-owned they are not working on razor-thin gross margins – and this is a good thing for you!

Public companies and PE firms are absolutely possessed with EBITDA (Earnings Before Interest Taxes & Depreciation/Amortization). This is a quick metric that will tell them if they are performing well or not. Some PE firms have their EBITDA target set at say 15%, and they will not look further into acquisition if it is less than that. Do you know your company’s EBITDA %? If not, please reach out to me, and we will do an analysis for free.

If you did not sell your label company to PE during the buying frenzy for whatever reason, did you miss that opportunity? Absolutely not. Not every label company owner wants to sell or have a boss. When you sell your baby to a PE firm, let there be no mistake, you will have a boss. Keep running your label company as you have in the past, but you have been given an opportunity to spiff-it-up for yourself or a potential sale at some point in the future.

You should focus on getting your financials organized to present multiple years at a glance. What you will be looking for is to get to your EBITDA. This is a quick metric that will tell you how you are doing. If your EBITDA is less than 10% (of sales), you have some work to do.

I am sure you are aware that all public companies have an outside Board of Directors. PE-owned companies have them, as well. I suggest that if your company has more than $5 million in sales, you should have a Board, too. You can call it a Board of Advisors, if you prefer. Your Board should include major shareholders and at least three outside individuals. I would shoot for finding one person having each of the following skills: manufacturing, sales, or finance. It is not necessary that these individuals be from the label industry. The problems you might have at your company are not related to the products you produce.

You should have quarterly Board meetings with an agenda and circulate your company’s internal financial statements a week or so prior to the meeting. This will be quite humbling for you at first but a very good discipline. I would encourage you to pay your Board members something – say $1,000 per meeting plus out-of-pocket travel expenses for starters. You should not include your CPA or attorney on your Board.

In conclusion, I believe having public companies and even more PE firms in the label industry is a healthy thing to have happen. There will be fewer (albeit stronger) converters who will tend to price their products to produce healthy gross margins. Just make sure that if you do not sell your label company to a PE firm, that it remains on strong financial footing by getting solid reports from your CPA – a compilation at a minimum and more preferably a review of your firm’s sales in excess of $7.5 million. Should you have any questions about the content of this column, please do not hesitate to reach out to me.

Jim Anderson is the Founder & President of Scottsdale, AZ-based Corporate Development Associates (CDA). CDA is a boutique Merger & Acquisition consulting firm that has focused 100% on the printing industry since 1987. Website: www.printmergers.com. Contact Jim via email: janderson@printmergers.com or cell/text: 602-432-0426 

I understand the concern; however, with one-fifth of the world’s oil blockaded behind the Strait of Hormuz, we’re potentially facing “the worst disruption to energy supplies since the oil shocks of the 1970s.”

It’s rather ironic that the potential oil crisis is coming just a month after the Environmental Protection Agency repealed the scientific determination that gives the government the authority to combat climate change, otherwise known as the “endangerment finding.” 

The endangerment finding was arguably the biggest US governmental response to air pollutants since the Clean Air Act of 1970. The Clean Air Act required the government to regulate air pollutants that harm human health but stopped short of regulating greenhouse gases. In 2009, the Obama Administration signed the endangerment finding, stating that six greenhouse gases, including carbon dioxide and methane, “threaten the public health and welfare of current and
future generations.” 

These gases are released by the combustion of fossil fuels such as when a car engine burns gasoline or a power plant burns coal. Repealing the endangerment finding allows the EPA to roll back pollution limits on the oil, gas, and coal industries. It could also hinder future administrations from reinstating any climate rules, as the justification for addressing greenhouse gas emissions has been dismantled. 

The scientific basis for this repeal is…nonexistent. Let’s attempt to ignore our partisan biases and look at the facts. Our president insists that climate change is a “hoax,” and “the greatest con job ever perpetrated on the world,” despite 97% scientific consensus that human-caused climate change is happening. I present to you some comments: 

American Chemical Society: “Earth’s climate is changing in response to increasing concentrations of greenhouse gases and particulate matter in the atmosphere, largely as the result of human activities.”

American Geophysical Union: “Based on extensive scientific evidence, it is extremely likely that human activities, especially emissions of greenhouse gases, are the dominant cause of the observed warming since the mid-20th century. There is no alternative explanation supported by convincing evidence.”

US National Academy of Sciences:  “Scientists have known for some time, from multiple lines of evidence, that humans are changing Earth’s climate, primarily through greenhouse gas emissions.” 

I could use up my entire word count pasting comments from every single reputable scientific community stating that 1) climate change is real, and 2) it is caused by human activity. To argue otherwise would be willful ignorance. 

Yet, Americans are still skeptical about human-induced climate change. According to a recent Pew Research Center survey, 25% of Americans say humans are contributing “not too much” or “not at all” to climate change. Republicans are far less likely to see a human impact – the survey says 44% of Republicans don’t believe humans are contributing to climate change.

This skepticism has played out in recent energy policy and investment decisions. All federal emissions standards for cars from 2012 onward, including fuel economy standards, were repealed. The US ceased all contributions to the Green Climate Fund, which assists developing nations with climate adaptation. We’ve subsidized coal-fired power plants to the tune of $175 million, required new renewable energy projects on federal land to match the energy output per acre of fossil fuels, and accelerated the expiring of wind and solar tax credits while keeping incentives for “enhanced oil recovery” and carbon capture used for drilling. 

I realize this isn’t a political commentary column, but I find it impossible to ignore the, frankly, asinine approach to climate change our government is taking. It’s antithetical to science, common sense, and the benefit of the American people! 

Where does this leave us as an industry? We need to ignore the changing whims of whatever administration is in power and remain committed to the big picture. If we set stricter requirements for ourselves than the law requires, we build a “policy-proof” business. Where regulation can’t move the needle, capitalism can. 

To do this, we must consider: 

1. Are we tracking carbon emissions at our facilities? You can’t manage what you don’t measure.
2. Do you have a plan to tackle scopes 1, 2, and 3 emissions?
3. Where does your energy come from? How will you reduce reliance on fossil fuels? Is it time for solar or a power purchase agreement?
4. Are you transparent? Are your customers able to see the steps you’re taking to reduce emissions, or are you relying on vague promises? 

The government has abdicated its role as the protector of our climate. That’s a tragedy, but it’s also an opportunity for leaders to step forward. Because at the end of the day, the government can repeal a finding, but it cannot repeal the realities of a warming planet – nor can it stop a customer from choosing a competitor whose values (and carbon math) are better than yours.

Ginnie Gandy leads the Release Liner division at Channeled Resources Group. She is passionate about the release liner, label, and packaging industries. Ginnie is also the  chair of  TLMI’s Label Leaders of Tomorrow group and is a regular presenter at industry events.

That may sound like an obvious statement, but it is one that is often overlooked in an industry that has long been driven by equipment specifications, production speeds, and technical capabilities. Dscoop Edge served as a reminder that even as the tools evolve, the success of any operation still depends on the decisions, mindset, and leadership behind them.

From a technology standpoint, the direction of the industry feels increasingly clear. Digital printing continues to expand its role across label and packaging applications, supported by ongoing improvements in quality, speed, and versatility. At the same time, workflow integration and automation are no longer optional – they are becoming fundamental requirements for converters looking to remain competitive. The demand for shorter runs, faster turnaround times, and greater customization is not slowing down, and digital platforms are uniquely positioned to meet those needs.

During his keynote, John Koller, SVP of HP Print Marketing, challenged attendees to “partner with the future,” a phrase that encapsulates much of what the industry is currently facing. That future is not defined by a single technology, but rather by the ability to integrate multiple systems into a cohesive, efficient production environment. Koller also pointed to an interesting dynamic that continues to play out across markets: in an increasingly digital world, physical print retains a powerful and, in some cases, growing role. Brands are rediscovering the value of tangible communication, particularly when combined with data-driven personalization and targeted messaging.

Complementing this perspective, economist Taylor St. Germain of ITR Economics provided a broader view of the business environment, outlining expectations for moderate but steady growth through 2026 and beyond. His outlook suggested a relatively stable economic landscape, but one that leaves little room for inefficiency. For converters and print providers, this means that while opportunities remain, success will depend on disciplined execution, cost management, and strategic investment. In other words, the market is not going to carry anyone forward; companies will need to position themselves carefully and operate with precision.

Taken together, these insights reinforce a central point: the roadmap for the industry is not particularly ambiguous. The technologies are known. The trends are well documented. The opportunities are visible. And yet, for many companies, translating that knowledge into consistent performance remains a challenge.

This is where the conversation at Dscoop Edge Rockies 2026 took an interesting turn.

One of the most compelling sessions at the event had little to do with printing technology at all. Nick Santonastasso, an entrepreneur and keynote speaker, delivered a presentation centered on mindset, resilience, and leadership. Born with Hanhart syndrome – a rare condition that left him with no legs and one arm – Santonastasso shared his personal experiences as a framework for navigating adversity and uncertainty.

Early in his talk, he made a statement that resonated with the audience: “We all have struggles – you can just see mine.” It was a simple observation, but one that immediately shifted the focus from external challenges to internal perspective.

Santonastasso’s central message was that success, whether in business or in life, is driven less by strategy and more by psychology. “The game is always psychology,” he said. “It doesn’t come down to strategy – it comes down to how you think.” For an audience of print professionals accustomed to solving problems through process improvements and equipment upgrades, this was a different kind of conversation.

And yet, it felt highly relevant.

After all, most converters today are not lacking in awareness of what needs to be done. They understand the importance of automation, the benefits of workflow integration, and the need to improve efficiency and reduce waste. The strategies are not a mystery. The difficulty lies in execution, and execution is ultimately influenced by leadership, culture, and mindset.

Santonastasso introduced the concept of  “focus patterns” – the ways in which individuals direct their attention, often unconsciously. He challenged attendees to consider whether they tend to focus on what they have or what they lack, on factors within their control or those outside of it, and on the future at the expense of the present. These patterns, he suggested, shape not only individual performance but also organizational outcomes.

In an industry where day-to-day operations can be consumed by deadlines, production pressures, and customer demands, it is easy for leaders to become reactive rather than intentional. Over time, this can lead to a kind of operational autopilot, where decisions are driven more by immediate concerns than by long-term strategy.

Closely related to this idea was Santonastasso’s discussion of what he called an “emotional home” – the state that individuals tend to return to most frequently. For some, this may be a positive state characterized by confidence, clarity, and purpose. For others, it may be dominated by stress, frustration, or uncertainty. Regardless of where someone falls on that spectrum, the key point is that these emotional patterns influence behavior, decision-making, and, ultimately, results.

“Your state is most of the battle,” he said, emphasizing that leadership is not just about what you do, but how you do it.

This theme was echoed in a different way by Lori Gottlieb, a psychotherapist and bestselling author, who explored the human side of leadership, relationships, and communication. Her session reinforced the idea that effective leadership requires a level of self-awareness that goes beyond technical competence. Understanding how people think, react, and interact is critical, particularly in environments where change is constant and expectations are high.

For many in the audience, these sessions provided a valuable counterbalance to the more technical aspects of the event. They served as a reminder that even the most advanced production systems are only as effective as the teams operating them.

This brings us back to the broader implications for the label and packaging industry.

As converters continue to invest in new technologies and expand their capabilities, the competitive landscape is becoming increasingly defined by how well organizations can integrate those tools into their operations. Automation, digital printing, and workflow systems can deliver significant advantages, but only when they are implemented thoughtfully and supported by strong leadership.

In practical terms, this means aligning teams more effectively, particularly across functions such as sales, production, and operations. It means fostering a culture that embraces change rather than resisting it. And it means recognizing that performance is not solely a function of equipment, but of people.

Dscoop Edge has long been known for its strong sense of community, and that was evident again this year. Beyond the formal sessions, the event provided ample opportunity for attendees to share experiences, exchange ideas, and learn from one another. These interactions are often where the most valuable insights emerge, as they reflect the real-world challenges and successes that define the industry.

In many ways, that community-driven aspect of Dscoop may be its greatest strength. While technology continues to evolve, the ability to connect with peers, gain perspective, and build relationships remains a constant. It is through these connections that ideas are tested, refined, and ultimately implemented.

Looking ahead, the path forward for the industry appears both promising and demanding. The growth of digital printing, the push toward greater automation, and the increasing importance of sustainability will continue to shape the market. At the same time, economic conditions will require companies to operate with greater discipline and efficiency.

The tools are available. The opportunities are there. The question is how effectively companies can bring all of these elements together.

If there is a single takeaway from Dscoop Edge Rockies 2026, it is that the future of print will not be defined solely by technology. It will be shaped by the people who adopt that technology, the decisions they make, and the way they lead their organizations through change.

In an industry that has always prided itself on innovation, that may be the most important evolution of all.

Steve Katz is the former editor of Label & Narrow Web and is now a regular contributor. He is focused on helping companies in the label industry share their news and tell their stories. Follow him on X @LabelSteve.

“The new DateCodeGenie Mini lets operators label anywhere – back of house, front of house, or on the move,” says David Webster, sales director, NCCO International. “From independent cafés to enterprise chains, it keeps teams compliant, consistent, and efficient.”

The DateCodeGenie Mini is an all-in-one handheld solution that transforms food safety in many applications, from multi-site foodservice outlets to small, independent shops. It can be used to add allergens, ingredients, pricing, expiry dates, barcodes, and QR codes, all managed from the centralized online portal.

Extending DateCodeGenie beyond the kitchen, DateCodeGenie Mini can standardize labeling and compliance across multiple sites with centralized templates and reporting. While staff have a portable, easy-to-use tool, managers gain full visibility and control to reduce risk, save time, and drive efficiency at scale.

Portable and practical

The DateCodeGenie Mini is an all-in-one handheld solution built for busy foodservice. Cable-free and compact, it prints easily readable labels instantly. No handwriting, no ink, no fuss. With a long-lasting battery, businesses can rely on it through service, wherever it is needed.

DateCodeGenie Mini is compatible with NCCO’s high-performance labels that maximize roll capacity and minimize waste – supplied in rolls of 500 (50mm x 25mm) and 250 (50mm x 50mm).

Smart and supported 

Running on Android with an intuitive 6.7″ touchscreen, the DateCodeGenie Mini is easy for staff to learn and use, and training and 24/7 support comes as standard.

Each device includes a 7,500 label starter-pack, with 5,000 50mm x 25mm labels and 2,500 50mm x 50mm labels. And businesses can order more labels whenever they are needed.

Reliable and future-ready

Backed by NCCO’s global infrastructure, the DateCodeGenie Mini comes with a 2-year warranty (extendable to 3-years on ordering) and ongoing software updates.

DateCodeGenie Mini is fully compatible with NCCO’s DateCodeGenie product family and can also go beyond labeling. With a separate subscription to NCCO’s Task Manager tool, teams can manage digital HACCP checklists, complete daily compliance tasks, and keep critical documents up to date. The combination of DateCodeGenie and Task Manager provides oversight, improves efficiency, and helps maintain high Scores on Doors ratings, all from a truly portable device.

Transforming food safety

“Own each device outright, then with one simple monthly subscription, users have access to the full DateCodeGenie software portal, ongoing support and updates,” concludes Webster. “Compatible with high-performance labels supplied in rolls of 500 and 250, the DateCodeGenie Mini will make labeling simple and efficient, saving your team hours each week.

“Trusted by thousands of businesses worldwide, DateCodeGenie Mini delivers compliance and consistency you can take anywhere.”

Solutions lie in a well-orchestrated combination of human and AI processes. Neither, by itself, is sufficient. Together, they can provide a robust review process that eliminates many potential issues before they become brand-damaging events. 

Notes a blog posted by GlobalVision software company: “Labeling errors are deceptively simple on the surface yet capable of causing far-reaching impacts. The food and beverage industry, like all highly regulated industries, must recognize that accurate packaging and labeling is more than a compliance requirement; it’s a trust-building service that keeps consumers safe…Many companies still rely on outdated, manual proofreading, leaving room for human error, fatigue, and missed details…allergen-related recalls are rising…Automated proofreading (like GlobalVision) catches text, graphics, barcode, and braille discrepancies before products reach consumers, improving speed, accuracy,
and compliance.”

The post adds that preventing errors and omissions depends on audit processes, investing in automation, training teams, and monitoring recall trends to spot risks arising in the marketplace.

Various stressors are exacerbating errors. Besides a general lack of attention or competency among proofers, many products now must develop labels and packaging for many countries. Accuracy can get lost in translation. Ironically, this is where human eyes can sometimes supersede the ability of AI systems. Humans can detect subtle nuances and language idiosyncrasies that AI may miss.

GlobalVision identifies other stressors and solutions: “Manual proofreading processes remain the Achilles’ heel for many regulated companies. Humans are inherently prone to oversight and fatigue, particularly in high-pressure production environments where speed and volume are critical. Labeling errors often occur at bottleneck moments like final packaging or transition phases between product lines.”

Overviewing quality control and assurance steps, GlobalVision suggests:

• Auditing current procedures. Find where the errors occur, then address. They can come from graphic design, printing, or labeling operations;
• Investing in technology. Besides improving accuracy, technology can amp up efficiency and speed;
• Train your team. No technology is entirely foolproof. Equip the team so they understand how to interpret automated inspection findings and intervene where required;
• Monitor trends. The marketplace will provide valuable intel about how, where, and how often problems occur. Monitoring also identifies regulatory changes. Proactivity can help businesses stay ahead of common pitfalls and develop a culture of safety-first protocols.

Other considerations identified by GlobalVision encompass:

• Compliance. Evolving regulations create a moving target of compliance. Given such challenges as increasing allergen-related recalls, brands are re-evaluating their quality control procedures and upgrading their systems and processes;
• Silos. Cross-team reviews, coupled with AI, can prevent many problems. However, when non-communicating silos prevail, mistakes multiply;
• Including AI in the mix. Notes the GlobalVision post: “Automated proofreading software integrates seamlessly into production workflows, checking artwork, files, texts, and graphics against original designs. Imagine a digital safety net that scans product packaging to spot even minute discrepancies before products reach the consumer. Whether the error stems from physical misalignment or a swapped ingredient, these tools are designed to catch inconsistencies early, ideally before production even ramps up…Automation also creates a paper trail of quality checks, providing clear proof of compliance in the event of audits or investigations.”

Every product vertical can be researched to determine where to start to ensure accuracy. For example, in the food industry, Food Safety Net Services (FSNS) works with customers to deliver the “right stuff.”  They offer a six-step label control process for food manufacturers.

When all is said and done, another ingredient in label accuracy is plain, old-fashioned common sense. While AI may be able to incorporate common sense into the mix, at its core it’s a distinctly human ability. In addition to all the formal human and AI review processes, eyeball everything to determine if anything seems amiss. For example, micrograms (mcg) and milligrams (mg) are two frequent ingredient measurements. This is an area of high potential for mistakes. If a particular product dosage is typically listed in milligrams, seeing a microgram designation on a label is a likely red flag. In today’s complex, fast-moving, and error-prone environment, product manufacturers are well-advised to be especially diligent when creating labels and packaging to ensure accuracy and full disclosure.

Mark Lusky (www.markluskycommunications.com/mark-lusky-bio) is the president of Lusky Enterprises, Inc. (www.markluskycommunications.com), a 41-year-established marketing communications company dedicated to clients that live and breathe trust, likeability, and respect (thereby eschewing the “lie, cheat, steal” culture so prevalent today). Contact him at: 303-621-6136; mark@marklusky.com.

Flexography has evolved from a manual artform to a technological powerhouse. Automation and data now play a huge role in shaping converters’ print runs. 

According to Nilpeter, flexo represents the backbone of global label production, and that will continue. “The most significant trend we see is the shift from manual operation to intelligent manufacturing,” states Martin Teilberg, global head of marketing, Nilpeter. “Flexo today is no longer a mechanical discipline alone – it is increasingly software-driven. Automation has moved from being a competitive advantage to becoming an operational necessity. We see strong demand for automated registration, closed-loop color control, servo-driven platforms, automatic job recall, and fast, predictable changeovers.”

“The digitalization of our process allows us to collect data utilized by AI algorithms to create an environment of machine learning where AI can be used to mitigate human interactions,” adds Paul Teachout, business development, Omet Americas. “Digitalization creates data-driven, predictive modeling of our workflows. Our products must transform the way companies monitor, manage, and interact with their machines, enhancing efficiency, productivity, and technical support.”

Flexo is evolving quickly, meaning presses are also providing more packaging types. “Web widths are shifting – digital continues to absorb ultra-short-run label work, while wider inline flexo is gaining traction across unsupported labels, flexible packaging, and specialty applications,” states Katie Graham, regional marketing and communications manager, Bobst North America. “Increasingly, converters are also leveraging data and AI-driven insights to simplify operations and optimize performance.”

Technology has advanced to keep up with the latest challenges facing converters today. “Flexo converters are facing many of the same pressures we see across the wider label industry,” comments Werner Krummenacher, Gallus sales head, Market Region Americas. “Flexibility is becoming increasingly important, with businesses looking for platforms that can evolve with them over time, giving them the confidence that their investment will continue to deliver value as market requirements change.  At the same time, margins remain under pressure. That makes efficiency and productivity on the shop floor more critical than ever. The ability to run complex jobs with fewer manual interventions, and with greater consistency, is becoming a key factor in maintaining profitability, which is why we’re seeing increasing demand from customers around automation, ease of use, and faster setup.”

For many of the industry’s leading converters, flexo is still paramount across their operations. Inovar Packaging Group, for example, relies on flexo across numerous sites. “Flexo is still our most efficient platform for longer runs and repeat programs,” explains Brent Berthiaume, director, Prepress & Color Control, Inovar Packaging Group. “It is ideal when brands scale up from digital volumes. Plus, flexo is the best option when coatings, specialty finishes, or durability matter. It’s important to note flexo works alongside digital instead of competing with it.”

Converters are increasingly relying on real-time data to optimize their companies, especially with respect to their flexo runs. “Our customers want actionable production data in real time – not just machine statistics, but insights that support better decision-making,” adds Teilberg. “Through collaborations, such as our work with Catapult Print, we have seen how structured data collection leads to measurable improvements in uptime, reduced waste, and more consistent output. The goal is simple: keep the press running and eliminate
unplanned downtime.”

The newest flexo presses can also serve numerous markets. “One of the major trends we’re seeing is traditional label converters using flexo as a springboard into adjacent print formats, especially flexible packaging,” says Ben Luly, product manager, Mark Andy. “A half decade ago, for many label converters that felt like a big leap. Now, it’s increasingly part of the growth plan, and flexo remains a practical way to expand into films and new structures with the right configuration and workflow.  

“We’re also seeing steady interest in short-run shrink applications,” adds Luly. “That space has matured. Converters are getting more deliberate about where shrink fits in their production mix, and they’re looking for equipment and processes that let them handle it profitably.”

Despite the massive improvements in flexo technology, suppliers like Nilpeter and Bobst have emphasized modularity with their newest launches. “Our presses are built for long service life,” comments Teilberg. “Many of our installations operate successfully for decades. For that reason, we also invest heavily in upgrade programs, bringing the latest software, controls, and hardware improvements to machines already in the field. This protects our customers’ investments, enhances performance, and extends operational lifetime without necessarily replacing the entire press.”

“New-generation presses deliver higher levels of automation, connectivity, and flexibility, helping reduce complexity across the entire production workflow,” adds Graham. “Modular platforms, such as those from Bobst, allow converters to integrate multiple processes into one line, streamlining operations from job setup through to production and performance monitoring.”

From a press performance standpoint, LED curing is another popular trend. LED curing supports more energy-efficient production, reduces running costs, and can contribute to a lower total cost of ownership while also supporting sustainability goals. 

“We design our platforms with this flexibility in mind,” says Krummenacher. “On the Gallus RCS platform, for example, existing curing units can be retrofitted with switchable LED devices. While on the Gallus Labelmaster platform, customers can choose between mercury and LED curing depending on the inks and varnishes they wish to use. This allows converters to select the curing technology that best fits their applications while expanding the range of compatible inks.”

Suppliers have also diversified their portfolios to a place where they can work with customers on finding the right technology for their book of business. For example, Mark Andy offers flexo, digital, and hybrid press solutions.

“We can help a converter think through what’s best for their business, their customer mix, and their operational realities without steering them toward one technology just because it’s the only one we can offer,” says Luly. “Some converters want to stay in flexo because they’re excellent at it, they have a disciplined process, and they don’t want to add complexity or technical risk that they’re not staffed to manage. That can be a smart choice. Others have the strategy and the internal capabilities to take the next step into hybrid or digital because it aligns with where their customers are going.”

“At Gallus, we believe the future of label production will not be defined by a single technology,” adds Krummenacher. “There’s undoubtedly a place for conventional, digital, and hybrid solutions, and as the lines between these technologies become increasingly blurred, having expertise across all of them is essential to help customers identify the most suitable and profitable production approach.”

Redefining the pressroom

Even in recent years, there has been a misconception that a label converter had to choose digital or flexo for their print shop. These technologies work side by side, and selecting the right print method is key to optimizing efficiency. The evolution of both technologies – along with the emergence of hybrid – has altered the dynamic of the pressroom.

“Digital continues to own short runs and versioning,” notes Inovar’s Berthiaume. “Meanwhile, flexo has had to get faster at setup to stay competitive, with quicker make-ready and changeovers. Hybrid production is more common, with digital for variable data and flexo for speed and cost efficiency. Customers expect tighter color matching between both platforms now.”

“Flexo is moving toward more versatile, high-value production – complementing digital while simplifying the overall production mix and enabling converters to handle multiple applications on a single platform,” adds Bobst’s Graham.

Digital and hybrid printing have reshaped the allocation of work across a label printing facility, too. Speed plays a major role here.

“High-speed digital continues to push into job lengths that were historically ‘safe’ flexo territory, and that crossover point has moved substantially as digital speeds have increased,” states Mark Andy’s Luly. “Flexo has lost share in certain segments, particularly shorter runs with high versioning. However, the bigger impact is the way converters define efficiency now. The conversation used to be very focused on ink cost and raw speed. Today, it’s more about total throughput and how quickly you can move jobs from the order received to labels on a pallet shipped out the door.”

However, what was once considered a digital or flexo run is constantly evolving. Digital and hybrid presses can run longer. Therefore, collaboration with suppliers is critical when it comes to  choosing the right press for the targeted book of business.

“What’s clear is that run lengths are continuing to shorten and the break-even point for digital production is evolving,” says Gallus’ Krummenacher. “That means digital is becoming viable for a wider range of applications than it was just a few years ago, which naturally begins to blur the lines between technologies. In the short to medium term, this will likely accelerate the adoption of hybrid approaches – either through integrated presses that combine flexo and digital within a single system, or through a broader ‘hybrid’ printshop floor and production mindset, where converters have the flexibility to choose the right technology for each job.”

Converters must account for numerous variables when estimating a job, from setup times and platemaking bottlenecks to changeovers and troubleshooting. The ability to run consistently – job after job – will dictate success.

Hybrid, meanwhile, offers the best of both worlds. “Hybrid sits in a middle ground for a lot of converters,” adds Luly. “It allows them to keep flexo where it’s strongest, bring in digital where it adds value, and avoid forcing every job into one lane. That flexibility has changed the buying mindset. Converters are building pressrooms around production strategies, not around a single print process.”

“There is room for digital, hybrid, and flexo,” adds Nilpeter’s Teilberg. “The optimal choice depends entirely on the converter’s business model, run lengths, substrate mix, and customer requirements.”

Omet, for example, has partnered with Durst for its hybrid solutions. For the short and mid-run length jobs, hybrid presses deliver a consistent color gamut with virtually no setup time and a full complement of finishing technologies all on a traditional flexo web transportation platform – all in one pass.

“Over the years, I have seen printers have up to 25-30% of their production be short run work, and printers struggled with quick-turns on traditional flexo presses where they needed to push out 12 jobs a day,” explains Omet’s Teachout. “The digital hybrid solutions of today have helped overcome that challenge. We have seen over the last decade that hybrid presses can overcome that 25%, freeing up the traditional flexo presses for longer runs. Now, when I enter the most efficient facilities, I see one hybrid and three flexo, or two hybrid and six flexo and so on.”

When investing in a new press, Inovar has several requirements in mind. “We’re looking for automation that actually reduces setup time, with automated impression, registration, and more,” adds Berthiaume. “Reliable color control systems, such as ink metering, anilox and tape systems, are critical, as well. Ultimately, we need press data that helps us track performance and reduce downtime.”

Focusing on the workforce

The workforce challenges facing the label manufacturing industry continue to loom large. The advancements of flexo will play a critical role in hiring and retaining employees, especially as long-time flexo press operators retire from the workforce. Suppliers are designing presses that will attract today’s future flexographers.

“Ease of use is critical,” says Bobst’s Graham. “Modern presses are designed with intuitive interfaces, guided workflows, and connected technologies that reduce operator dependency and simplify day-to-day operations, making the production environment more accessible and efficient.”

“New technologies offer relief to the growing workforce challenge,” adds Omet’s Teachout. “Omet customers continue to request platforms that provide ease of use and a short learning curve. Providing operators with simplicity and ease of use, quicker setup features, and automated register and print controls are a must.

“A big part of attracting the younger generation to our trade is to convince them that this is not a down and dirty manufacturing process of the past, but that of a very sophisticated, clean-hand production process utilizing the most advanced technologies in the world,” continues Teachout. “We have evolved our process from rubber to photopolymer, gear driven to servo motors, and with the advent of AI we now move from automation to autonomation. Simply put, we are entering the next industrial age, from 4.0 to 5.0 and from disruptive to regenerative.”

In most cases, the prospective employee anticipates a technology-friendly process. “The next generation expects intuitive systems, digital interfaces, and connected environments,” says Nilpeter’s Teilberg. “Modern flexo presses reflect that. Touchscreen interfaces, recipe-driven job setup, remote diagnostics, and integrated data dashboards make the press environment more accessible and less dependent on manual adjustments. Young professionals are attracted to technology that feels advanced. Automation, AI-driven optimization, and data-based decision-making make flexographic production more aligned with modern industrial engineering.”

Technology now is the name of the game with the newest flexographic innovations, especially with the difficulty in recruiting new employees. “Hiring is hard, training is harder, and retention is a real issue,” explains Mark Andy’s Luly. “In a lot of pressrooms, tribal knowledge is walking out the door, and the next generation of operators often hasn’t had the same apprenticeship-style runway that earlier generations had. That reality is directly shaping equipment requirements.”

Therefore, the newest press technology must reduce the dependency on “the one person who knows how to run that press,” adds Luly. More automation, fewer manual steps, and fewer opportunities for variation make it easier to train people, maintain consistency, and run at a high level across multiple shifts. The workflow must also become more intuitive and repeatable. 

For Inovar, the newest flexographic technology makes training a simpler and more intuitive process. “It feels more like running a technical system than purely mechanical equipment,” says Berthiaume. “They are easier to train on now compared to older presses. There are cleaner setups and fewer manual tweaks with quick change die systems, for example. And there are more screen-based (digital) controls and less mechanical adjustments such as buttons vs. knobs.”

However, technology can’t be the only solution. While collaboration is often discussed, it needs to happen within converting facilities, as well as between suppliers and customers.

“Attracting the next generation is not only about new technology – it’s also about ensuring knowledge is passed on,” states Gallus’ Krummenacher. “As the industry prepares to hand the baton to the next generation of press operators, it’s crucial that we continue transferring technical expertise and best practices. That is why we established the Gallus Print Academy, which provides ongoing training and education to help customer teams maximize the performance of their equipment and build the skills needed for the future. Together, these elements form part of our broader vision for smart, connected printing – creating production environments that are not only more efficient and automated but also supported by continuous learning and collaboration across the industry.”

In order to continue grappling with this challenge, technology will need to improve – but so too must the efforts of suppliers and converters in touting the industry. “The challenge has been and will continue to be recruitment and retainment,” comments Teachout. “We must entertain the next generation workforce in their decision-making years – in high school, supporting career days and apprenticeship programs to share our industry and all the opportunities it has to offer. This needs to be done at the grass roots level. If there’s a workforce challenge in your area, find a way to connect with this demographic and share the opportunities our industry presents – a very sophisticated, intelligent and rewarding career path.”

Flexographic innovation

Bobst continues to focus on solutions that connect workflow, equipment, and data. The company’s newest presses and technology reduce complexity across the full lifecycle, from file to finished product and beyond. The goal is simple: enable converters to make faster decisions, run more efficiently, and scale with confidence.

As a supplier of flexographic and digital/hybrid solutions, Gallus is focused on continuing to evolve its flexographic platforms while also advancing its broader portfolio. This ensures customers have access to the right solutions, whichever direction the market takes them.

“This fits closely with our System to Compose concept, which allows customers the flexibility to expand their production setups over time, for example by incorporating digital printing units alongside conventional processes where it adds value,” remarks Gallus’ Krummenacher. “A good example of development in the flexo space is the continued success and evolution of the Gallus Labelmaster. With the recent addition of the 22″ configuration, converters can now achieve even higher productivity, particularly in sleeve applications and high-volume label production.

“We are working to change mindsets, and to integrate conventional, hybrid and digital technologies into more intelligent, connected production workflows and ecosystems,” adds Krummenacher. “By combining advanced workflow solutions, such as Heidelberg Prinect, converters can gain greater visibility, automation and efficiency across their entire production environment.”  

Meanwhile, Mark Andy is helping converters simplify decisions and reduce variability in the pressroom.The company has highlighted an automation strategy, SmartSet, which is designed to reduce setup complexity and help converters improve throughput by minimizing touchpoints and making changeovers more efficient and consistent. This type of automation targets the constraints converters are dealing with: fewer experienced operators, compressed lead times, more job variety, and the need to keep presses running predictably day after day.

“Mark Andy’s newest press platforms also reflect how converters are evolving their production mix,” says Luly. “The Performance Series S9 flexo press is built for those who need high-speed label productivity but also want a press that can support expansion into mid-web flexible packaging and unsupported film applications, with performance designed to handle both traditional label work and the demands that come with more challenging substrates at speeds of up to 1,000 fpm.”

Nilpeter continues to refine intelligent registration systems, automated color control, advanced servo technology, and faster changeover procedures. These directly improve uptime and reduce waste.  

“Within data and connectivity, we support enhanced machine data capture and integration with customer workflows,” notes Nilpeter’s Teilberg. “Experience from projects such as Catapult Print demonstrates that structured data use translates into real operational savings.”

Omet is committed to providing the most advanced narrow and mid-web packaging platforms available that can adapt and evolve with growing technologies. 

“On the software side, the digitalization and connectivity we offer has set the bar in predictive production modeling,” states Teachout. “Connectivity to external systems with specifically designed industrial machinery software is crucial.”

Plus, Omet Virtual Access is a multilingual app used for the management of maintenance and assistance activities and remote installations. Tasker, meanwhile, manages production jobs with greater simplicity and agility, ensuring better integration with MIS/ERP systems, defining the new connectivity standard between Omet machines and customer industrial systems. The Omet Job Card Manager is cloud-based software that manages recipes on the machine in a unified manner, distributing them among all groups so as not to lose them in case of PC or machine damage.

As the flexible packaging market represents more than 40% of all flexo-produced packaging, Omet offerings begin at 14″ and go all the way through to 42″ in width.

“Our new KFlex, launched at Labelexpo Europe, also displayed our new Switch platform,” adds Teachout. “This is a convertible platform that allows you to switch modules within the press from flexo to offset to rotary screen or even a die station, making this the most convertible press in the market and ideal for hybrid solutions.”

When inconsistency arises, in many cases, label converters should look to the anilox. “Making sure you have the correct line screen and volume that will work with your artwork and graphics is key,” states Eduardo Suarez, marketing manager, Harper Corporation of America. “If your anilox specs do not work with your art, you will have dirty screens while running, and the color will also not match your end user’s expectations. On the other side of that, if your specs are not correct to your coating requirements, the outcome will also be lacking in appearance, or your coat weight will not be sufficient.”

There are several trends inherently present with the newest anilox technology. “Manufacturers are currently pushing anilox technology in two parallel directions: re-engineering engraving geometry in search of the holy grail of ink transfer, and driving resolution ever higher to meet tightening color tolerances,” explains Adrian Buratta, sales and marketing director, Troika Systems. “A great deal of effort is being spent on reinventing traditional cell structures, moving away from the long-established 60° hex cell toward open-channel, continuous, and hybrid engravings that aim to improve ink release rather than simply increase theoretical volume.”

There are numerous factors to keep in mind regarding hybrid engravings, too. “Line count and volume alone do not define performance,” remarks Jake Roberts, sales director, Sandon Global. “Two anilox rolls with identical specifications can behave very differently depending on cell geometry, wall structure, and depth. Hybrid engravings provide converters with greater flexibility to optimize ink transfer based on the specific application, rather than being constrained by traditional resolution-volume trade-offs.”

In the US narrow web market, Sandon Global has seen strong adoption of its hybrid technologies. “Many converters have successfully transitioned from conventional 60° engravings to hybrid formats such as Fluid UV (combination solid and tonal print) and Fluid Hex (process and solid 60°), with some standardizing their entire anilox inventories around these solutions to improve consistency and efficiency,” adds Roberts.

At the same time, manufacturers are aggressively pushing line screens into the 1800+ LPI range and beyond. “The motivation here is clear: finer engraving supports higher screen rulings, smoother vignettes, and tighter color control, with many aiming to approach one Delta E or lower,” states Buratta. “However, this race for finer LPI also exposes the practical limits of physics. Extremely small, deep cells can struggle to empty reliably, meaning that without precise control of cell geometry, higher LPI does not automatically translate into better print. As a result, advances in laser engraving technology are as much about controlling cell shape, wall smoothness, and opening width as they are about absolute resolution.”

The newest technological advancements have targeted the most pressing flexographic challenges, as well. “Anilox scoring remains one of the most frustrating and costly challenges in the flexographic printing world,” remarks Sam Benson, technical sales representative, Provident. “Despite the wide awareness of its effects, many printers still struggle to pinpoint its root causes and prevent recurrence. Darker, more prominent lines signal more severe damage, a physical gouge in the roll. These scores disrupt ink flow significantly and cannot be reversed. At this stage, recoating or replacing the anilox roll is typically required.”

New anilox rolls bring their own set of challenges. Dried inks, coatings, and substrate residue can quickly build up and compromise the fine cells of modern rollers, leading to issues like uneven ink laydown and higher overall ink consumption.  

“While modern rollers can achieve higher resolution than older models, their cells are often smaller and shallower,” notes John Rustidge, global technology director, Chemicals, Flint Group. “This means they are more prone to clogging if the correct preventative maintenance programs aren’t in place. Even minor contamination can alter ink density or weaken color strength. And while today’s advanced rollers are often more durable, they still require compatible, non-aggressive cleaning methods to avoid premature wear or loss of critical cell geometry.”

Most every variable can be scrutinized for printing success. “Converters must assess everything from what material is used, how those materials are being applied, down to the processes when manufacturing with those materials and tools,” remarks Suarez. “They all play an important role. If your process and quality of materials are not in place, this will cause two rolls with the same specs to not print the same. This is huge when converters are trying to cut down on setup time and waste.”

Anilox technology is also being impacted by the latest in automation and AI. Anilox development is no longer purely mechanical, as it has become increasingly data driven. Digital modeling, simulation, and feedback from pressroom measurement systems are being used to design, validate, and refine engraving patterns before they ever
reach production. 

“In parallel, connectivity and data capture allow converters and manufacturers to link anilox performance to real press results, supporting predictive maintenance, tighter process control, and more repeatable outcomes across sites,” notes Buratta. “Taken together, these trends show an industry striving not just to engrave finer or differently, but to make anilox performance more measurable, more predictable, and more aligned with the demands of modern, color-critical
flexographic printing.”

To deliver consistency, there have been significant product launches. For example, Harper has engineered a new XCAT engraving. With this new hybrid engraving, Harper’s pocketed channel can provide smoother laydowns with less pin holing, decreased spitting, no trail edge voids, and quicker cleanups.

In addition to the XCAT geometry, Harper has launched zero VOC AltraWash Clean. With zero VOCs, it is easy on the environment and safe for all ink systems. Meanwhile, Optimization+ is a program offered by Harper’s Technical Services Team. The offering has been  crafted based on FIRST certification principles, using academic, technical, and scientific methods to help customers become well-tuned with their suppliers, increase productivity, tighten up tolerances, and increase press efficiency.  

Meanwhile, Troika offers a comprehensive range of products and services designed to bring precision, consistency, and efficiency to the printing and packaging industry. Buratta says, “At the core of the offering is the AniCAM EVO, a high-resolution 3D scanning system that enables accurate inspection of anilox rollers, ensuring that ink transfer and coating performance meet exacting standards.”

Troika Systems also provides anilox quality control tools, including measurement and verification solutions that help companies maintain consistency across production runs.

Quality control is paramount when working with the anilox. “Quality control in anilox management is absolutely critical – more than many realize,” adds Buratta. “Anilox rollers are the unsung heroes of the printing process: they directly govern ink transfer, line screens, and ultimately the consistency and vibrancy of the print. 

“Quality control is a core part of our offering,” states Roberts. “Sandon’s in-house metallurgical laboratory in the UK enables detailed analysis of coating structure, hardness, and porosity to ensure consistency, durability, and performance across every anilox supplied. This level of control supports reliable ink transfer, improved print consistency, and extended service life.”

In order to account for quality, having the right procedures in place is also key. “There should be a process in place that determines the anilox based on the print outcome that is needed,” notes Benson, adding, “An anilox can also be the reason there is dirty printing or the cause of or lack of color/density.”

Assessing the flexo process

While converters should immediately look to the anilox roll when dealing with inconsistencies, numerous other factors could define the success of a flexographically printed job. For example, various plate and ink technologies could also impact the run – or the anilox. Therefore, working with suppliers when implementing new technologies could lead to more immediate success.

“Many customers think that doctor blades are the only reason for score lines, but in fact, there are a multitude of causes,” states Provident’s Benson. “Operators need established and detailed SOPs and audit protocols to ensure proper blade installation, seating, and chamber alignment. Otherwise, a good amount of troubleshooting goes into finding the root cause.”

According to Benson, hands-on evaluations and vendor collaboration can identify several key culprits that emerge consistently. These include:

• Doctor Blade Issues 
Misaligned or improperly seated blades can scrape across the roll surface, especially under excess pressure, creating score lines over time. 
• Ink Contamination 
Poorly milled inks may contain oversized particles that wedge between the blade and roll, contributing to both scoring and cell plugging. 
• Pressroom Debris 
Dust, substrate fragments, or foreign material can enter the chamber and embed between the blade and roll, causing surface damage. 
• Anilox Manufacturing Defects 
Flaws like slag, recast, or irregular engraving patterns, especially in low-LPI rolls, can predispose the roll to early scoring or uneven wear. 

“A flexo press is fingerprinted with certain plates, sticky back, anilox and doctor blades,” explains Benson. “There could be an issue if one is changed – then the print outcome could be altered.”

As ink and plate technologies advance, the importance of systematic anilox roll cleaning is only growing, too. Advanced photopolymer plates can now transfer ink so precisely that even minor contamination on   the anilox surface can significantly influence tonal range and image uniformity. 

“This is particularly problematic as the popularity of energy-curable inks continues to grow, as these formulations create harder, more stubborn residues that demand stronger, non-damaging cleaning chemistry,” comments Flint Group’s Rustidge. “These trends, combined with the growing demand for faster press speeds and shorter runs, underscore the need for fast-acting, reliable cleaning. Converters need to be able to quickly and effectively maintain the presses with minimal turnaround between jobs. In this context, cleaning becomes a decisive factor in maintaining color accuracy and press efficiency.” 

Coating quality is another critical factor that is often overlooked. “The hardness and porosity of the ceramic layer directly influence wear resistance, ink release, and long-term performance,” says Sandon Global’s Roberts. “Without monitoring these properties at every single stage, it is impossible for anilox suppliers to guarantee coating consistency.”

Working with a reliable vendor can help pinpoint many such issues that arise on-press. “Depending upon the type of change made, we like to work with the customer and monitor print quality,” states Harper’s Suarez. “All the different components play a big role in print quality, and when one changes, the others will be affected. Building quality relationships with our customers and understanding the why and how the changes are made, we can get a good idea if the changes will affect the anilox and what recommendations will be needed.”

Working with your suppliers

With anilox technology advancing at a rapid pace, collaborating with suppliers is critical for printing success.

“Since we work with all types of printing applications, our requests are widespread,” comments Harper’s Suarez. “We always like to work with our customers to define their expectations, gather all information that is needed for their application, and try to work with all departments and co-suppliers that will be involved so we can have a collaborated effort. Once all parameters have been defined, we will be onsite for the testing and provide support until the project is completed.”

Flint Group’s discussions with customers consistently uncover several key priorities, namely reducing cleaning time, eliminating cleaning processes that could cause damage to the roller surface, and doing so with safer, lower-VOC cleaning solutions. The company’s Enviroflex portfolio represents a holistic approach to protecting anilox performance while still supporting converters’ sustainability goals. Each formulation has been developed with the same precision as modern anilox roll technology, ensuring compatibility and longevity across flexographic workflows.

“Flint Group Packaging Solutions works collaboratively with converters to embed preventative, structured maintenance regimes that optimize overall equipment effectiveness and secure more consistent printing,” says Rustidge. “The company’s range of cleaning products are engineered to address the full range of contamination challenges with purpose-built chemistries matched to specific applications.”

Flint Group focuses on collaboration, as well. Flint Group Packaging Solutions’ technical teams advise converters on cleaning best practices. Support is available to help converters align their chemistry with automated wash systems and balance cleaning frequency with productivity. 

“Working in partnership with customers, Flint Group provides tailored maintenance strategies to ensure print quality remains as vibrant on the 1,000th impression as on the first,” adds Rustidge.

Provident offers a host of products and services to the industry. The company provides a wide mix of doctor blades that work with the anilox to support keeping it in the best shape that it can be to print quality material. For example,  doctor blades made from high-quality Swedish steel can last longer and have less wear on anilox rolls. “With many material and tip options available, operators are sure to find the best type of blades for all their specific printing needs,” says Benson.

Sandon Global’s portfolio includes conventional cell designs, plus innovative engraving technologies including Fluid UV, Fluid Hex, High Opacity White (a flexo alternative to rotary screen), and its patented GMX Anilox for tricky coating applications. These engravings are designed for both process and specialty applications, addressing common narrow web challenges such as ink spitting and coatings with large particle deposits.

Beyond hardware, Troika Systems also provides consultancy and process optimization services, helping converters implement best practices in roller management, color control, and production efficiency. “Our approach is not just about tools, it’s about empowering businesses to make data-driven decisions, reduce waste, and improve overall print quality,” states Buratta. “Troika combines precision technology with expert guidance to support every stage of the print process.”

Apex International launches Anilox Armor

Apex International has announced the global launch of Anilox Armor, a new line of premium protective covers engineered to safeguard anilox sleeves during storage, transport, and handling. The product is now available worldwide through Apex and its regional partners.

Anilox sleeves are precision-engineered components that play a critical role in delivering consistent ink and coating transfer across flexographic, coating, and other advanced printing processes. In today’s production environment, especially with the growing adoption of ECG printing, correct anilox usage is essential to minimizing downtime and maintaining print consistency.

The end-ring color identification adds significant value by allowing anilox sleeves to be quickly and accurately identified, handled, and stored. This ensures seamless recognition across all operators and shifts, reducing errors and improving efficiency.

In addition, effective protection is vital. Damage sustained during storage or handling can compromise the engraved surface and lead to print defects, downtime, and higher operating costs. Anilox Armor covers are specifically designed to address these risks. The product safeguards converters’ anilox sleeves and extends the lifespan of anilox assets.

“Anilox Armor introduces an added layer of protection that reinforces Apex’s mission to help customers achieve maximum reliability, extended lifespan, and superior performance from their precision anilox sleeves, whether using conventional engraving or Apex’s patented GTT technology. At Apex, we are committed to ensuring our customers feel fully supported and clearly see the long-term value of partnering with a truly customer-centric supplier,” says Nick Harvey, technical director, Apex International. “We listened to what pressrooms say causes the most costly damage, and we engineered a solution that protects these critical components from impact, abrasion, and environmental stress.”

Anilox Armor protective covers combine impact-resistant composite materials with a precision-fit, air-cushioned interior. This feature absorbs shock and prevents contact damage to critical engraved surfaces. Apex specifically engineered the covers for Apex sleeves and rolls. The design ensures a secure, non-slip fit that resists inks, solvents, and cleaning agents.

Key features include air-cushioned dual-layer protection for impact absorption during handling and transport, as well as durable FRP Construction that resists abrasion and repeated use. Plus, color-coded handling rings are used for fast identification and efficient pressroom workflows. The products also feature chemical resistance against inks, solvents, and cleaning agents, and they include a reusable design that minimizes waste and offers long-term value.

Anilox Armor reflects Apex’s decades of experience in anilox technology and its commitment to innovation across the full lifecycle of pressroom assets. By protecting engraved surfaces from common damage points, the new covers help reduce unnecessary reworks, downtime, and replacement costs.

“In many facilities, damage happens during routine movement and storage,” adds Harvey. “Anilox Armor helps address that risk proactively, so presses stay running, and high-quality print standards are maintained.”

Apex stocks Anilox Armor in standard sizes to fit commonly used sleeve and roll diameters, with custom sizes available upon request to match specific applications and workflows. Apex will showcase the product at select industry events and trade shows throughout 2026.

Flexible packaging’s growth is being fueled by strong demand across key end-use markets. Analysts estimate the global flexible packaging is valued at more than $350 billion, with steady annual growth projected through the end of the decade. According to research from Smithers, demand for flexible packaging is expected to expand at a rate of roughly 4-5% annually, outpacing many traditional packaging formats.

Much of that growth is being driven by food and beverage applications, which account for more than half of total demand, as well as continued expansion in sectors such as pharmaceuticals, personal care, and e-commerce. At the same time, brand owners are accelerating commitments to more sustainable packaging, with a growing emphasis on recyclable and mono-material structures by 2030. Together, these trends are reshaping both material development and converting strategies across the value chain.

For converters, the question is no longer whether flexible packaging is growing – that has been well established. The more relevant question is if, and how – and to what extent – it fits into their long-term strategy.

A natural extension for label converters

In many respects, a move into flexible packaging is a logical progression for label converters. Core competencies like web handling, color management, and digital workflow integration translate well into flexible packaging production. Meanwhile, brand owners are looking for partners who can offer a broader range of packaging solutions – a one-stop-shop, so to speak – from pressure sensitive labels to pouches and other flexible formats.

This convergence – a word being used a lot these days in the package printing industry – is being accelerated by the continued push toward shorter runs, faster turnaround times, and greater SKU proliferation. As brands look to differentiate on-shelf and respond to shifting consumer demand, the ability to produce smaller quantities efficiently becomes critical. Digital and hybrid technologies have played a major role in enabling this shift, and many of those same platforms are now being adapted for flexible packaging applications.

Still, the transition is not without its challenges. Flexible packaging introduces a different set of requirements, particularly in areas such as barrier performance, sealing, and substrate compatibility. For converters accustomed to working primarily with labels, these factors can represent a significant learning curve.

Sustainability drives innovation

If there is one factor shaping the flexible packaging segment more than any other, it’s sustainability. Regulatory pressure, brand commitments, and consumer expectations are all driving change across the value chain.

In Europe, the much talked about Packaging and Packaging Waste Regulation (PPWR) is accelerating this shift, with phased requirements that will impact material selection, recyclability, and overall packaging design. Similar trends are emerging in North America and other regions, creating a global push toward more sustainable solutions.

For flexible packaging, this often means moving away from traditional multi-material laminates toward structures that can be more easily recycled. That, however, is easier said than done.

Flexible packaging has long relied on complex, multi-layer constructions to deliver the barrier properties required to protect products – particularly in food and beverage applications. These structures can include multiple polymers, coatings, and adhesives – all working together to preserve freshness, extend shelf life, and ensure product safety. The challenge is that these same characteristics make them difficult to recycle through conventional systems.

From multi-material to mono-material

In response, suppliers across the industry are developing new approaches designed to balance performance with recyclability. One of the most notable developments in this area is the shift toward
mono-material structures.

Bobst, for example, has been at the forefront of this movement with its oneBARRIER family of products. The portfolio includes PrimeCycle, a polyethylene-based structure, and FibreCycle, a paper-based alternative. Both are designed to replace traditional multi-material packaging while maintaining the barrier properties required for demanding applications.

Initially introduced as prototypes, these solutions have since been validated at commercial scale, demonstrating that recyclable structures can meet real-world production and performance requirements. For converters, this represents a significant step forward, as it brings sustainability-focused materials closer to everyday production environments.

At the same time, it highlights the complexity of the transition. Not all applications require the same level of barrier performance, and developing solutions that align with specific product needs remains a key area of focus.

Rethinking barrier requirements

One of the more interesting developments in flexible packaging is the recognition that ultra-high barrier performance is not always necessary. In some cases, a medium-to-high barrier may be sufficient, depending on the product, its sensitivity, and the intended shelf life.

This shift has the potential to simplify both material structures and converting processes. By reducing the number of layers or coatings required, converters can move closer to solutions that are easier to recycle while also improving efficiency on-press.

It also opens the door to new material combinations and processing approaches, creating additional opportunities for innovation. As suppliers continue to expand their portfolios, converters will have more options to match specific applications with the appropriate level of performance.

Behind oneBARRIER

To learn more about Bobst’s oneBARRIER technology, we caught up with Sara Alexander, marketing and communication manager, Flexible Packaging, Bobst.

LNW: What has been the impact of oneBARRIER to date?
Sara: oneBARRIER, and what it represents, is a real game-changer, and we are starting to see its impact expand for our customers. Sustainability is a central focus for all our customers, but the technical complexities of developing and manufacturing sustainable flexible packaging with the right, recycle-ready barrier can be daunting.

By combining our oneBARRIER know-how with our vacuum metallizers and coating lines, Bobst can help converters to consistently produce top quality polyolefin-based or paper-based recycle-ready ultra-high or high barrier packaging, with faster time-to-market from day one. Many of our customers are already benefiting from this, which, in turn, is supporting wider sustainability goals.

LNW: So, what’s next for oneBARRIER?
Sara: From the beginning, the vision for oneBARRIER has been for a family of solutions. This means that on one hand we can develop many different combinations and solutions with our partners based on the market needs, availability, and convertibility. On the other hand, converters are able to choose the right solution for their situation.

A key focus for Bobst is currently broadening the oneBARRIER family and expanding its applications. For example, we need to work on solutions with different substrates and chemicals. We also need other options than just ultra-high barrier solutions. We need different barrier solutions for different market situations. And we need to find ways to simplify the process even further. So, we are exploring a lot of exciting options.

LNW: Can you talk more about going beyond ultra-high barrier solutions? Why would we need packaging that doesn’t provide an ultra-high barrier?
Sara: Not all food packaging requires an ultra-high barrier because the necessary protection level depends entirely on the specific food’s sensitivity, desired shelf life, and storage conditions. For many products, a medium-to-high barrier is sufficient. And for some, such as certain types of cheese that get ruined within a completely airtight seal, it’s necessary.

So, we are investigating a medium-to-high barrier solution. And that instantly helps to simplify the process too, because it is developed without the primary, first coating pass. It’s an exciting development, and we look forward to sharing more information on this soon.

LNW: Can you see oneBARRIER being introduced for other industry sectors such as folding carton and corrugated in the future?
Sara: Yes, certainly. We’re not quite there yet, but research and development is happening at pace. And because we now have all the experience of developing oneBARRIER in flexible packaging, it gives us a bit of a head start.

LNW: What other key trends can you see in the future?
Sara: I think we will start to hear a lot more about home compostability, as well as recyclability. We have to be pragmatic. Many countries still have little recycling infrastructure. Compostable packaging can be disposed of in an environmentally responsible manner and is becoming increasingly readily available, driven by rising consumer demand, regulatory pressure, and material innovations. Now it’s about making it really viable on an industrial scale, making it machinable. I think this will be a very interesting trend to watch in the future.  

Technology and process considerations

While materials are a critical piece of the puzzle, technology and process control remain equally important. Flexible packaging production places a premium on consistency, particularly when it comes to print quality, registration, and sealing performance.

Advancements in press technology, including improvements in flexographic printing and hybrid configurations, are helping to address these requirements. Automation is also playing an increasingly important role, enabling converters to streamline workflows, reduce waste, and improve overall efficiency.

At the same time, inspection and quality control systems are becoming more sophisticated, allowing converters to detect defects earlier and maintain tighter tolerances throughout the production process.

For label converters entering the flexible packaging space, these considerations underscore the importance of investing not only in equipment, but also in process knowledge and operator training.

Innovation on display

The pace of innovation in flexible packaging is perhaps best illustrated by the Flexible Packaging Association (FPA) Achievement Awards, which continue to serve as a barometer for where the industry is heading.

This year’s competition – marking the program’s 70th anniversary – featured 108 submissions across 360 category entries, with 28 packages ultimately earning 36 awards. The breadth of winners reflects a segment evolving on multiple fronts simultaneously, from sustainability and materials science to printing innovation and shelf impact.

At the top of the list is the POUCH3 Cuboid format from Sun Centre USA, which earned the competition’s Highest Achievement Award. The design reimagines traditional pouch geometry, delivering a box-like, headspace-free structure that uses up to 30% less material than conventional formats while maintaining functionality and shelf presence. Built from a recyclable mono-material polyethylene structure, it highlights the industry’s push toward circularity without sacrificing performance.

Sustainability-driven innovation was a consistent theme across many of the top entries. A standout example is the Australian Organic Vanilla Custard mono-material retort pouch, developed by Flavour Makers and Cheerpack Asia Pacific. The structure represents a significant advancement in retort packaging, combining full recyclability with the high barrier performance required for shelf-stable food applications – long considered one of the more difficult challenges in flexible packaging design.

Other entries demonstrated how sustainability and performance are increasingly being engineered together. SmartSolve’s water-soluble pouch technology, for example, provides a biodegradable alternative for single-use applications, while PaperWave air cushions – made from 100% recycled paper with a compostable structure – illustrate how flexible packaging is expanding into protective and e-commerce applications with reduced environmental impact.

Printing innovation was equally well represented. Bryce Corporation’s transition of Doritos packaging from a seven-color expanded gamut to a four-color flexographic process showed how converters are pushing the boundaries of color management while reducing ink usage and improving press efficiency. 

Similarly, Nosco’s digitally printed Koeze pouch highlighted how high-end tactile finishes and variable graphics across multiple SKUs can be achieved without compromising barrier performance or
production efficiency.

Shelf impact and consumer engagement also remain critical drivers. Printpack’s Harry Potter Butterbeer Goldfish packaging leveraged metallization and bold graphics to create a premium, limited-edition look designed to stand out at retail, while other entries incorporated matte finishes, varnish effects, and advanced embellishments to enhance visual appeal.

For FPA competition judge Fred Crowe, managing partner of Crowe and Associates, the most striking aspect of this year’s competition was not just the individual innovations, but the pace at which the industry is advancing.

“It’s been a real pleasure…seeing the ingenuity and engagement of converters, their customers, and their suppliers,” Crowe said of the judging process. “They’re bringing incredible ideas to execution.” 

That execution, he noted, has accelerated significantly in recent years.

“The amazing thing to me is the execution that has taken place and how dramatically it has progressed over the last two or three years,” Crowe said. “You see a significant amount of new technology being brought to the forefront, along with creativity – not only from converters, but also from product development teams – finding ways to solve these challenges.” 

Taken together, the award winners reinforce a central theme: flexible packaging is not evolving along a single path. Instead, progress is being driven by a combination of material innovation, process optimization, and creative design – often within the same package.

Looking ahead

As flexible packaging continues to evolve, converters are faced with a range of decisions about where – and how – to participate.

For some, the move into flexibles will be a natural extension of existing capabilities, supported by investments in new equipment and processes. For others, it may represent a more significant shift, requiring a reevaluation of business models and market focus.

What is clear is that the segment will continue to grow, driven by the same forces that are reshaping the broader packaging industry: sustainability, efficiency, and the need for differentiation.

At the same time, the lines between labels and flexible packaging are becoming less distinct. As technologies converge and customer expectations evolve, converters that can bridge these categories may be best positioned to capture new opportunities.

Ultimately, success in flexible packaging will depend on more than just technology. It will require a combination of technical expertise, strategic vision, and a willingness to adapt to changing market conditions.

For label converters, that may represent a great challenge – but also a great opportunity.

Enhancing shelf appeal with cast and cure technology

NBi FlexPack, a Wisconsin-based manufacturer of custom flexible packaging, has introduced its use of a technology that utilizes electron beam (eBeam) coatings to create cast and cure graphics on digitally-printed packaging. Cast and cure is a process that imprints a custom watermark or holographic effect on flexible packaging finishes like security marks on ID cards. 

“NBi FlexPack is one of the few companies in the world that has a custom made 30″ eBeam cast and cure unit,” says Jeff Leto, vice president of sales, NBi FlexPack. “This technology gives us the power to offer brand owners a competitive advantage over their competition to give their packaging star power to attract consumers with its distinct embellishment, as well as the latest advancement in brand protection.” 

By leveraging eBeam technology, NBi FlexPack’s cast and cure solution creates striking visual effects through light reflection. The  result is a highly distinctive appearance that immediately draws consumer attention on store shelves. In addition to its visual impact, the technology provides a powerful layer of brand protection. The embedded holographic or watermark elements are extremely difficult for counterfeiters to replicate, helping brands safeguard their products and maintain consumer trust.