Flexography Report

Article from Label & Narrow Web: In a new report from Smithers, the global value of flexographic printing in 2024 was $230.5 billion, and that figure is projected to increase at a 3.0% CAGR through to 2029.

Automation, data, and modularity are but a few of the trends impacting this dominant label printing process.

In recent years, digital printing has gained the lion’s share of attention in the label and package printing industry. Faster speeds, better quality, and automation, among other advantages, have propelled converters to flock to digital. However, the same could be said of flexographic printing, which still accounts for the vast majority of label runs. There is no slowdown expected for this market, either.

In a new report from Smithers, the global value of flexographic printing in 2024 was $230.5 billion, and that figure is projected to increase at a 3.0% CAGR through to 2029. Data from its newly published market report, “The Future of Flexographic Printing Markets to 2029” shows this will yield a total value of $267.2 billion in 2029 – at constant 2023 pricing. The report illustrates that flexo output is growing across most applications, with packaging emerging as a standout. Growth in this segment is forecast to continue, driven by economic demand from e-commerce and consumer-facing boxes, among others. Flexible packaging, labels, and folding cartons will see strong growth, as well.

“We continue to see a lot of interest in flexo presses of all widths, from 13″ (330mm) to 26″ (660mm),” says Scott Warhover, chief technology officer, Mark Andy. “There is an emphasis on practical automation, anything that increases the ease of use of the machine.

Flexography has not stayed stagnant. Brent Berthiaume, director of prepress and color control, Inovar Packaging Group, notes advancements in automation, sustainability, expanded color gamut (ECG), and hybrid printing as key differentiators in the modern flexo label printing market. Mark Andy has also seen more inline flexible packaging and high machine customization with flexo, including projects such as inline RFID insertion.

There are a host of other trends, too, which have modernized flexo. These trends will continue to drive adoption, leading to many of the aforementioned growth figures.

“As the flexographic market continues to evolve and expand, many of the current innovations revolve around the digitalization of the production process,” explains Paul Teachout, marketing and technical content specialist, Harper Corporation of America. “Cloud-based production management tools, which include MIS and ERP data collection, are now the norm as printers and converters pursue efficiency gains. Real-time data collection on flexographic printing presses, including that of third-party integrations, are now providing intelligent platforms. This level of connectivity and data collection will support future implementations of AI predictive modeling for production management. This collective intelligence will support the entire operational objectives from quoting, supply chain management, asset utilization to logistics.”

“There’s been significant development in workflow integration between presses and MIS software, with the increased use of data analytics and AI to support better decision-making in production operations,” adds Richard Miedema, global sales director, MPS Systems. “For example, MPSConnect enhances automation by seamlessly integrating into production workflows. It eliminates the need for operators to handle administrative tasks, allowing them to focus on printing.”

Meanwhile, Bobst Connect is a cloud-based digital platform that enables users to have a complete overview of their production process, from the PDF to the finished product. Designed to allow converters to improve productivity, maximize efficiencies and eliminate waste throughout the production process, Bobst Connect is continually updated with new capabilities.

Mark Andy has relied on data to improve the printing process for its newest presses. For all of the company’s machines, Mark Andy has developed ProWORX Analytics. This serves as a real-time monitoring system with cloud-based data storage, providing access to dashboards and data pertaining to productivity, up-time, and the Overall Equipment Effectiveness (OEE) of each machine.

“Our new S9 press incorporates the latest in automation for register and inking/impression control,” says Warhover. “The automatic registration control from the S9 will of course be available for the Performance Series, as well.”

Nilpeter has utilized the latest technologies to buoy its “The Future is Flexo” mantra. The Danish press manufacturer has emerged as a key partner for Catapult Print, a label converter based in Orlando, FL, USA. Here, Nilpeter has optimized Catapult’s processes to ensure it is on the cutting-edge of label printing.

“We are investing heavily in making flexo even smarter, more automated, and more sustainable,” states Martin Fjordlund Teilberg, global marketing manager, Nilpeter. “Collaboration is key. We don’t just develop technology in isolation – we work closely with customers and partners to create solutions that meet real-world challenges. A great example is our partnership with Catapult Print in Orlando, where we work closely with our Digital Shadow concept and data analysis to enhance production predictability and efficiency.”

The flexographic process has improved beyond the press, too. “Flexographic technology has been around for decades and has undergone continuous advancements – always evolving and improving. At Gallus, we offer robust, flexible, user-friendly, and high-performance flexographic printing machines,” says Alexander Kattner, product management, Digital Label Solutions, Gallus. “For example, by using different ink chamber types in combination with optimized doctor blade designs, a high production speed can be achieved with any flexographic ink type.”

Improvements in numerous supplies have helped boost converters, driving efficiency and profitability. “Since the mid-1970s, the flexographic process has been led by innovations in anilox roller technology and the evolution of photopolymer plates,” states Teachout. “Once a process of chrome and rubber, both are now a digitalized process with optimized chemistry and raw materials. Current anilox roller technology is made up of premium ceramic powders that yield extremely low porosity levels allowing digital fiber optic lasers to engrave any graphic image into the roller surface. Engravings can now be provided with the traditional 60-degree HEX engraving, which has been and continues to be the workhorse of flexo printing, with a channeled application technology. Things like UV ink spitting, reticulation, and air entrapment are greatly reduced, providing increased performance and efficiency. The relationship between the anilox roller and the plate has always been at the heart of our process and continues to evolve together.”

Curing has emerged as one of the biggest topics in flexo, says Kattner. “One major trend in flexographic printing is the use of LED curing instead of mercury curing,” he says. “This transition is driven by significant technological advancements in recent years as well as the increased availability of LED curable inks, which have become much more cost-effective. The advantages of LED curing for flexographic printing are undeniable. It aligns with the trend toward more sustainable and energy-efficient production while drastically reducing the running cost of the machine. This, in turn, reduces the Total Cost of Ownership and minimizes the carbon footprint of printed products.”

Plates now feature HD imaging, flat-top dots, and improved screening for faster processing and sharper detail, says Berthiaume. “Anilox rolls are categorized by high-line screens, laser-engraved coatings, and channeled engravings vs. traditional hex,” he explains. “Today’s servo-driven presses also feature automated tension control, faster setups, and improved consistency.”

“Microcell technology enables the use of lower anilox volumes, further improving ink transfer precision,” adds Jake Roberts, sales director, Sandon Global. “Hybrid anilox engraving techniques, such as Sandon Global’s Fluid UV engraving, further refine this process, balancing solid and tonal areas on the same plate for high-resolution, complex graphics. Overall, these improvements have made flexographic printing more precise, efficient, and adaptable to high-quality, sustainable production demands.”

Color has also reached new heights in flexo printing, specifically in regards to ECG. “Expanded Gamut remains a major trend in flexo printing, and it’s not going away anytime soon,” says Fjordlund Teilberg. “The ability to achieve a wider color range with a fixed set of inks offers printers better consistency, reduced waste, and more efficient production. However, success with ECG requires a full commitment – everything from color management and prepress workflows to press setup must be optimized to get the best results.”

Understanding each part of the process will better enable converters to troubleshoot problems. In many cases, obstacles go beyond the press.

“In reality, it’s often more beneficial to ensure that every step of the process is balanced and working in harmony,” says Gary Seward, managing director, Pulse Roll Label Products. “For instance, when considering changeovers and press make-ready, it becomes clear that job preparation remains a major bottleneck in label production. Simplifying this complex, time-consuming process by standardizing the parts and consumables required for make-ready helps printers maximize machine uptime, maintain a consistent rate of production, and minimize disruptions to the flow.

“An often-overlooked but crucial metric in this context is Right First Time (RFT). Achieving RFT means jobs are completed accurately from the outset, eliminating the need for reprints, adjustments, and the associated waste of time and materials,” adds Seward.

In the immediate future, sustainability will also impact the flexographic printing market, too. Designed to reduce waste and generate less energy usage, the entire process has evolved to better support the environment.

“Sustainability is playing a crucial role in the industry’s evolution,” says Alice Giorgi, sales and marketing assistant, Omet Americas. “Technologies such as UV LED curing, high-efficiency hot air drying systems, waste reduction strategies, and precise consumption control are all helping to make flexo printing more environmentally friendly while maintaining high performance and cost-effectiveness.”

Many of these trends will continue into the distant further, with a continued emphasis on automation. “Digitalization will drive flexo’s growth in a changing market, and the industry will continue to advance rapidly alongside the digital print packaging sector,” says Roberts. “By leveraging intelligent technologies and data-driven solutions, flexo converters and suppliers will be able to respond more quickly to customer needs and optimize production processes to continue to rival digital for longer runs, greater substrate versatility, and complex decoration.”

“Flexo holds a strong position in the market, and we do not see this changing anytime soon,” adds Kattner. “While digital offers advantages when it comes to flexibility and short runs, flexo remains the go-to solution for longer runs and will continue to play a crucial role within the industry.”

While digital printing has long been thought of as a competitor to flexo, there is a place for both technologies in a label converter’s shop. Flexo has notoriously been the go-to choice for long print runs, while digital is much more cost-effective on short runs – especially where multiple SKUs are involved.

“The flexographic process is still the primary printing process for the broader packaging market, with close to 80% of all labels still printed flexo,” says Harper’s Teachout. “The proliferation of the digital printing process has been amazing to witness, and this process continues to improve and expand its offerings in speed and resolution. Digital printing will only continue to provide further opportunities in the future, breaching other press platform verticals. However, I feel it is a direct complement to the flexographic process. It has offered converters the opportunity to provide their customers with enhanced offerings and shorter lead times.”

The way to gain true efficiency involves slotting the right job on the right press. That’s where utilizing both technologies properly can drive real success. “While technological advancements have brought a lot of attention to digital, what is often overlooked is the impact this has on flexo printing,” explains Mark Andy’s Warhover. “When the right work is moved to digital, it allows converters to better optimize their flexo operations, resulting in greater productivity and efficiency. These flexo machines also become real workhorses in these environments, right alongside the digital assets.”

Heidelberg-Gallus has established a modular process that is tailored to the unique needs of the printer. “We have successfully introduced our System to Compose, a concept that enables our customers to adapt to changing market requirements and our presses to evolve with the customer’s needs,” says Kattner. “For example, a roll-to-roll digital printing machine can be initially installed and later expanded into a full hybrid press, which will enable the customer to produce highly embellished, finished products.”

Bobst offers “the right solution for the right application” within its package printing press portfolio. Technologies include digital inkjet, All-in-One (hybrid), narrow web flexo, wide web CI flexo, and rotogravure. The company has made that the central focus of its new Atlanta Competence Center. The new facility is dedicated to serving customers in the label and flexible packaging sector, and showcases the press manufacturer’s flexographic, digital, and “All-in-One” hybrid technologies.

Hybrid printing has seen increased adoption as the technology has matured. “I think we see more of an integration between the two technologies moving forward,” explains Bill Kral, chief commercial officer, Inovar Packaging Group. “Hybrid printing allows brand managers to have the benefits of both technologies at their disposal. The color matching, opacity, specialized inks (metallized, thermochromic, industrial, etc.) and embellishments of flexo with quick changeovers, personalization, and perfect registration of digital – all in one pass – are now available.”

“The growth in digital technology enables the optimization of flexo assets as well, enabling increased productivity of both,” adds Warhover. “That, along with the continued growth of hybrid machines, secures the future of flexo printing as a major technology in this market space for the foreseeable future. Excellence in integration of flexo to digital will continue to drive hybrid advancements.”

The impact of digital printing on flexo has reached a point of stabilization, adds Omet’s Giorgi. “While it is true that digital printing has taken over some market share from flexo in recent years, it has also become clear that digital alone cannot replace everything that a flexo platform can achieve,” she says. “The versatility, cost-efficiency, and productivity of flexo printing remain unmatched for many applications. However, unlike standalone digital solutions, hybrid presses combine the advantages of both flexo and digital, making them a viable alternative that can further optimize production capabilities. This is where the real shift can happen, rather than a direct replacement of flexo by digital printing.”

“Since launching our Symjet in 2017, we’ve installed numerous hybrid presses worldwide,” says MPS’ Miedema. “We firmly believe in the synergy between inkjet and flexo printing, combining the strengths of both technologies. While digital printing offers clear benefits over analog, it also presents challenges such as different cost per label profiles and potential issues with reliability and consistency.”

Nilpeter, meanwhile, believes flexo and digital label printing are most successful when performed on their own – as opposed to in a hybrid environment. “Hybrid printing – combining flexo and digital in a single unit – has gained some interest, but it’s not the future of the industry,” states Fjordlund Teilberg. “While hybrid presses work well for certain applications, they come with limitations such as being unable to handle shrink sleeves effectively. We don’t see a booming market for hybrid; instead, the real growth is in wider flexo presses that can handle larger runs efficiently. That said, digital printing is finding its place. Printers are becoming more knowledgeable about when and where to use it. But rather than merging flexo and digital into a single machine, the future lies in seamless integration between separate flexo and digital workflows, allowing converters to optimize each technology’s strengths
without compromise.”

The workforce challenge facing manufacturing processes like flexography will continue to be a focal point for label converters. As many press operators reach retirement, the modernization of flexo will be critical in driving the process into the future.

“The workforce challenge is an issue that is not going away, as we will continue to see a diminishing number of human resources entering our industry,” states Harper’s Teachout. “The automated processes of intelligent platforms and digital hybrid technologies will help ease this pain. The journey of evolving our process from a craft to a science has now provided intelligent platforms in which HMI are providing more intuitive operation for the modern press operator. Included with automated and robotic operation, these HMI functions will provide a more predictable and repeatable result regardless of operator skill set. This will also help us reduce the need for human interaction throughout the manufacturing process.”

“The skills gap is not a new trend but continues to be perhaps the most critical challenge facing the flexo industry,” says Sandon Global’s Roberts. “While automation and AI will alleviate some pressures, we still need to upskill, train, attract, and retain new print experts to ensure a vibrant future for the flexographic industry. At Sandon Global, we believe that the industry must tackle this globally and collectively to safeguard the future success of the sector. Look at apprenticeship and work experience schemes, work with local schools or colleges and national trade associations to engage with and train the next generation in flexographic print. And implement succession planning to ensure that print knowledge, skills and expertise embedded within companies over many years is not lost once the more experienced workforce retires.”

The newest presses have been built with the operator in mind, one who has grown up with technology and is more inclined to benefit from a digitalized process. “The skilled labor shortage and workforce bottlenecks are impacting the industry, making it difficult to sustain growth and meet market demand effectively,” says Miedema of MPS. “The latest trends require advanced automation to streamline operations and reduce the burden on operators, fostering a more efficient production environment.”
In discussing Bobst’s machines, their global success, and automation being among the company’s four pillars shaping the future of packaging, Patrick Graber, product and marketing director at Bobst, says, “The output of the machine should not be impacted by the skill of the operator.”

“We’re designing machines that are easier to be operated, more consistent due to automation, and another answer to quality control,” concludes Matteo Cardinotti, head of Narrow/Mid Web, Bobst.

Nearly four years ago, Heidelberg USA relaunched its Apprenticeship Program in response to the growing shortage of skilled labor in the country. The vocational training initiative, designed to cultivate a new generation of field service technicians, has already proven successful, with several graduates now employed full-time by Heidelberg. Currently, the program is training 25 apprentices across its sheetfed, post-press, and Gallus product lines—its largest group to date. With plans to hire an additional eight apprentices within the year, the program is not only filling a critical skills gap but also serving as a model for how companies can invest in their future workforce.

The Heidelberg Apprenticeship Program spans 18 to 36 months and combines classroom instruction at the company’s Print Media Performance & Training Center (PMPTC) in Kennesaw, GA, and hands-on field training alongside a journeyman mentor within Heidelberg’s extensive network of service technicians. Apprentices are hired throughout the year, often beginning in the field and returning as a class to the PMPTC for a Fundamentals Training Course that covers every operating, electrical, and mechanical function on a Heidelberg press, in addition to pneumatics, software, and application.

“Bringing them in as a group helps build camaraderie and even friendly competition,” says Kimberly Wicker, skills development supervisor for Heidelberg. “This dynamic empowers them to rely on each other. Even as they move across the country, they frequently connect to share tips and troubleshooting challenges together.”

Heidelberg brought Wicker on board 18 months ago to support its Apprenticeship Program and other training initiatives. In addition to assisting with the hiring process, Wicker serves as a liaison and mentor for apprentices once they are hired. Her role helps apprentices—many of whom are new to both the company and the print industry—build a strong connection to Heidelberg. With retention critical to the program’s success, Wicker’s partnership with training manager Rogers English represents a new approach for the company.

“They really rely on Kimberly, especially in the early stages, for approval to ensure they’re meeting requirements,” explains Mike Koeberlein, VP of lifecycle operations for Heidelberg. “She keeps everything on track and ensures service managers stay engaged with the apprentices.”

Currently, Heidelberg USA boasts 25 apprentices at varying stages of completing their training. Of that, nine new hires are set to begin their Fundamentals Training course at the PMPTC in April. While the classes continue to grow, Heidelberg remains proactive in its efforts to refill its diminishing service force with a goal of having two classes of ten students per year.