Digital Printing: Transforming the Label Market
Digital printing in the label industry has evolved significantly, with a substantial portion of label converters integrating digital and hybrid presses alongside traditional flexographic equipment. As of 2024, digital printing accounts for 21.6% of the global label market value, according to a report by Smithers. This shift is driven by digital technology’s flexibility and efficiency for short print runs. However, converters increasingly recognize the importance of balancing digital and flexographic technologies to meet diverse customer needs and enhance operational efficiency.
Rethinking Print Technology Choices
Historically, the choice between flexographic, digital, and hybrid printing was primarily based on print run length: flexographic for long, consistent runs and digital for shorter, variable runs. However, relying solely on run length is outdated. The crossover point between technologies is not static; it varies depending on customer demands and operational priorities. Rigid adherence to these traditional distinctions can lead to inefficiencies, lost opportunities, and strained client relationships. Instead, versatility in technology selection ensures optimal resource utilization and maximizes profitability.
The hybrid printing market, which combines digital and flexographic technologies, is projected to grow at a compound annual growth rate (CAGR) of 12%, reaching approximately USD 16.53 billion by 2034. This growth underscores the increasing preference for hybrid solutions that offer flexibility and adaptability.
Optimizing Press Run Times and Resource Allocation
A key challenge for converters is balancing the availability of flexographic, digital, and hybrid presses to meet fluctuating demand. While maximizing run time for individual presses is crucial, considering the entire production ecosystem is equally important. For instance, a hybrid press may face downtime during flexographic setup, reducing efficiency. In contrast, using a separate digital press for certain tasks while handling finishing processes offline can improve overall productivity.
Additionally, shifting shorter runs from flexographic or hybrid presses to digital printing can free up resources for longer, more profitable jobs. This approach minimizes waste and reduces turnaround times. For multi-SKU jobs, where labels share common elements like dyes or finishes, hybrid printing can streamline production by consolidating setup processes. However, digital printing offers superior consistency and precision for tasks involving variable data or minor design variations.
Addressing Challenges in Transitioning Between Technologies
Smoothly transitioning between printing technologies presents its own set of challenges, particularly in maintaining image quality and color consistency. For example, shifting from flexographic to digital printing can result in discrepancies, even for standard colors. Flexographic printing, while robust, can exhibit color variations due to factors like heat and pressure, leading to rejected batches—some reports cite a 10–15% rejection rate due to inconsistencies.
Digital printing offers enhanced color accuracy and consistency, making it a preferred choice for tasks requiring precision. Some converters are now opting for digital printing even for traditionally "flexographic" jobs to ensure consistent results. However, until the design process accounts for potential variations across printing methods, the burden falls on converters to prioritize either brand consistency, cost savings, or operational efficiency based on their specific needs.
The Path Forward for Converters
There is no one-size-fits-all solution for labeling printing technology. Flexographic, hybrid, and digital processes each have unique advantages that contribute to overall operational efficiency. To remain competitive, converters must carefully evaluate their current and future needs, leveraging the right mix of technologies to meet customer demands.
Partnering with an innovation-driven solutions provider can help converters optimize their processes by identifying the most effective technologies and strategies for their workflows. This collaboration should extend beyond immediate needs to include long-term planning, ensuring that investments align with business objectives and market trends.
Conclusion
Digital printing and hybrid technologies continue to reshape the label industry, offering unprecedented adaptability and efficiency. By moving beyond traditional notions of run length and embracing versatility, converters can navigate the complexities of modern printing demands. Whether leveraging flexographic, digital, or hybrid solutions, the key to success lies in maintaining a balanced and dynamic approach tailored to the unique needs of each business.
For more information about Domino’s solutions, visit www.domino-printing.com.
Issued on behalf of Domino & Neo PR Limited.
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