LABELS AND

PACKAGING PRINTING
A DIGITAL OVERVIEW
LOOKING AT DIGITAL, HYBRID
and VARIABLE DATA PRINTING
LABELS AND PACKAGING PRINTING

CONTENTS

Variable Data Printing (VDP)/ Variable Information Printing (VIP)/ Variable Image
(VI) ...................................................................................................................................... 3

Consider Your Substrates................................................................................................ 9

Summary Of Digital Technologies................................................................................... 10

So What Should A Digital Printing System Provide....................................................... 11

Today’s Leading Label Printers Are Integrating Digital Technology Into Their
Analogue Printing Businesses......................................................................................... 11

What Questions Should I Ask A Digital Solution Provider?.......................................... 13

How Many Colours............................................................................................................14

Colour Management Software........................................................................................ 15

Workflow Software........................................................................................................... 16

Offline Finishing................................................................................................................ 17

Print Embellishment......................................................................................................... 18

Hybrid Combination Technology.................................................................................... 19

In Line Combination Printing........................................................................................... 20

Is A Hybrid Solution Right For Me?..................................................................................20

Attracting New Customers and Employees................................................................... 22

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VARIABLE DATA PRINTING (VDP) / VARIABLE

INFORMATION PRINTING (VIP) / VARIABLE
IMAGING (VI)
A new generation of digital
printing solutions provides
an excellent platform for
Labels and Packaging
producers. The technology
lends itself to the needs of
our customers, and we can
take advantage and
present solutions like
never before. Variable data
printing (VDP) (also known
as variable information
printing (VIP) or variable
imaging (VI)) is a form of
digital printing we are
concerned about, including
on-demand printing, in
which elements such as text, graphics and images may be changed from one
printed piece to the next, without stopping or slowing down the printing process
and using information from a database or external file.

The most basic level involves changing the message or name on each copy, much
like mail merge. More complicated variable data printing uses 'versioning', where
there may be differing amounts of customisation for different markets, with text
and images changing for groups of addresses based upon which segment of the
market is being addressed.

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This can take the form of personalisation which allows a company to connect to
its customers. With clever software, variable data printing can be more than a
variable name or address in a printed piece; in the past, a variable name would
have been effective, because it was a new concept at the time. In today’s world,
however, personalisation has to reflect what the customer values as important to
themselves.

Digital print is ideally suited to working with variable data printing. This is
often used in direct mailers and flyers or to tailor the print item to its recipient.
We can vary text, as well as images, on each item to create the biggest impact and
make each person feel special, ultimately personalising print to each recipient.

The creative use of digital QR Codes allows interaction through augmented reality
sites, website pages and social media platforms to expand the sales experience -
these applications have seen a dramatic increase in use throughout the Covid19
pandemic of 2020-2021.

One of the most common areas of use of VDP is Security and Tracking. The
application scores highly, and the use of unique barcoding on a product or
package can by useful for stock control, retail, tracking and pricing.
One cannot argue against the fact that digital printing is a valuable tool that has to
be welcomed alongside traditional printing formats, and in many cases, it is an
everyday part of the analogue printing process.

Almost everyone will have some experience of digital printing, either at home or
in the office through desktop printers, copiers and scanners. Digital technology
has made considerable steps forward in the narrow web and labels industry over
the past 20 years. There are now numerous digital technology platforms in the
marketplace with investment from under £5K for an offline printer to an
eyewatering £1.5M hybrid printing and converting line. But are they all equal and
which one is right for my business?

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Ink Jet Thermal Transfer

Thermal Transfer: Thermal-transfer printing is a digital printing method in

which material is applied to paper (or some other material) by melting a coating
of ribbon so that it stays glued to the material on which the print is applied.
Mono, colour and CMYK printing is possible. It contrasts with direct thermal
printing, which is mono printing only, where no ribbon is present in the process.
In this case, the substrate itself reacts to heat. In both cases, speeds are low, and
print quality is crude, but sufficient, for bar coding and simple graphics. Both
Thermal Transfer methods are treated as off-line print applications and in general
are found in companies who need an ‘in-house’ printing solution; for example,
warehouses, distribution, transport and tracking.

Digital Liquid Toner: When Benny Landa launched the Indigo digital press, few
saw the impact this new company would have on the world of print. After the
turbulent initial years HP has taken control of the Indigo and arguably has the
biggest share of Digital Press installations for the general commercial print
business. The system is an offset process where the image is initially printed with
liquid toners to a soft rotary blanket which, in turn, is transferred directly to the
substrate.

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Quality is excellent but materials require a special coating to optimise print

quality. Monthly service and ink charges can vary according to usage, and there is
also a click charge per print, much like you would expect with an office copier.
Xeikon have recently announced it is launching liquid toner in its range of
equipment. In general, you expect speeds of around 20 mts/min from basic
systems, therefore they tend to be standalone print engines with separate
finishing lines.

Digital Dry Toner: We are all familiar

with toner technology found in mono
and CMYK colour copiers in the office
and wider commercial printers. The
system uses heat to fuse/fix the image
to the substrate, which means there
are limitations for sensitive synthetic
substrate applications or substrates with rubber-based adhesive. The latest
systems from Konica Minolta under the Accurio banner can achieve printing
speeds between 23 to 40 Mts per minute. Also, Konica have just launched a
credible white colour option under the Accurio Label 400 model. Having over 800
installations, Konica are the leading supplier in this technology and Focus are a UK
distributer with operational equipment in its showroom.

Typical production set ups are a stand-alone print engine with separate
processing equipment for finishing. To find out more about the Accurio Label 230
visit our website.

Digital Memjet: The first Memjet systems were seen around 2010 and these
colour print engines can be found in a number of low-cost OEM systems under
various brand names. They fit somewhere between office and industrial use.

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The technology is ink jet and uses a water-based

dye rather than pigmented inks, which are
best suited to papers, it is generally not suitable
for synthetic materials unless as they are specially
coated. The system technology promises high
resolution, better than most digital alternatives.
Memjet have been very creative with OEMs, offering
stand-alone systems or hybrid solutions. Although the
initial system costs can be attractive, consumables such
as the ink and print head costs are extremely high in comparison to other high
end ink jet systems. Any special synthetic substrates that are pre-coated materials
will be expensive and you may need to over laminate to add protection to the
printed surface. Memjet technology are a good entry level option, as an
introduction to the technology. If you have an industrial application, we suggest
you test for colour fastness in difficult environments where the printed surface
requires scratch and rub resistance or exposure to sunlight.

Digital ink jet: Ink jet is a very

versatile digital print system,
finding itself used in virtually
all industrial print applications
from ceramics and tiling,
flooring, direct product decoration,
textiles, wood, security printing,
packaging and labels. Systems can
be multi-pass like an XY plotter or
single pass units and being compact can be integrated into product, web and roll
fed machines. A drop-on-demand print head has hundreds of microports, where
measured droplets of ink are fired onto the substrate as it passes under the head.

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Surfaces can be contoured or flat and the ink quickly fixed by drying through
evaporation or UV curing systems. Ink jet systems can print on a wider range of
substrates than other systems, some better quality than others. Print quality is
dependent on the surface tension at the point the ink hits the surface substrate,
and we would recommend serious testing. In recent years, digital ink jet has taken
over other methods in terms of print resolution (1000 /1800 dpi) and speeds are
now up to 50-120 mts/min for a single pass system. Compact ink jet engines can
also be easily integrated into existing machines for a combination of analogue,
digital and finishing solutions.

Hybrid Flexo, digital ink jet, plus die cutting , cold foil & converting

Learn more about dflex machines here and learn more about dpack machines
here.

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Digital Nanography: First launched in 2012 by ‘Landa’, finished systems were
promised for delivery for 2013. The first beta installations were supplied in
2020. By Benny Landa’s own admission they are a little late. The system uses a
revolutionary technique of digital printing to a flat offset blanket, the ink turns
to a uniform thin film which, according to the manufacturers, can be
transferred to ANY substrate, and no special coatings are required. Having
initially been marketed across a range of Print industry applications, ‘Landa’
now look like they will only focus on the wider web format for maximum
returns. Costs of equipment, inks, and servicing costs, click charges have yet to
be divulged, but will no doubt follow Mr Landa’s previous business models.…
Watch this space!

CONSIDER YOUR
SUBSTRATES:
The simple fact is that if you
select any of the above digital
systems they will not print on
ALL substrates with equal
quality. Some substrates will
print perfectly on one digital
technology but not another
type of digital technology.
The number of printable substrates are limited by the technology itself. Some
systems will require all substrates to be specially coated before printing, which will
be more expensive than standard materials. They may need an over varnish or
laminating layer to protect the printed image, adding to production cost. Some of
the digital systems can print on a small number of standard substrates straight
from the supplier, but others will require coating or pretreatment (Corona). To
optimise quality and keep costs down you may have to encourage your client to
use an alternative substrate.

SUMMARY OF DIGITAL TECHNOLOGIES

In summary, a typical printing business today may have a number of analogue
press technologies at its disposal to meet individual clients needs or production
costs. In a digital world, it is no different. These digital technologies are not equal -
each offer advantages and disadvantages so do your homework in deciding which
best suits your market and applications. In most cases a single digital
platform is not going to cover all your needs and you may decide you will require
2-3 digital technologies to match your clients’ needs and complement the range of
analogue presses you already have. Those wishing to replace analogue presses
with a single digital technology may be.
LABELS AND PACKAGING PRINTING

SO WHAT SHOULD A DIGITAL PRINTING

SYSTEM PROVIDE?
Instant Press proofs close to a client's approved print runs.
Instant costing for ink and substrates.
Reduced repro costs.
Fast turnaround times.
Production of small and medium press runs to meet each customer’s needs,
helping them manage their inventory more effectively.
Variable Data Print, sequential numbers, numerous barcodes and full colour
product personalisation of each printed image.
A variety of printable substrates.
A cost-effective print and finishing solution.
Consistency and reliability.

Today’s leading label printers are integrating digital technology into their
analogue printing businesses.

Whether it’s a mono digital ink jet printer mounted onto their Flexo press for
printing variable data, a stand-alone full colour digital press that serves as
operational relief to their Flexo, or a Flexo-digital hybrid label press, label printers
are realising the benefits that digital technology brings.

► Why is digital a complementary technology to Flexo?

Digital can add value to your end product without adding to the process or costs
of production. Indeed, by combining Flexo and digital you can take out additional
processing costs.

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► What are the drivers and trends for adding digital printing?
Small runs, personalisation, variable data, reduced inventory, response and
reduced lead times, initial proofing
► Who is adding digital printing to their business?
Most businesses are considering digital in some form for their commercial
applications. Fortunately, there are various entry price points to consider for
equipment solutions.
► When is the best time to add digital printing?
Any time now is a good time to start; with the ever-changing technology
landscape, waiting for tomorrow’s latest advance simply is not an option.
► How can I make and save money by adding digital printing?
You can reduce reprographics and plate costs by switching to digital, combining
processes to remove an operation. Some companies offer a trade print service to
other printers in the area, becoming a trade print hub for local companies. You
may wish to test the technology and grow your digital business by outsourcing to
a trusted trade printer until such time you have built enough business to warrant
investing in the technology.
► Where can I go to learn more?
Start on the internet, visit trade shows, and carry out trials with systems
manufacturers and talk to equipment suppliers.

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What questions should I ask a digital solution

provider?
On several levels, digital printing cannot be compared directly with conventional
printing systems. In-fact, each of the systems discussed can have a defined
appearance compared to each other and analogue printing. This is no different to
comparing the subtle differences in analogue print such as gravure, offset,
flexographic, letterpress and lithographic equipment.

Digital printing requires a lot of advance pre-press preparation in the presented

files - the saying ‘rubbish in, rubbish out’ is absolutely true in this case. In asking
the right questions and preparing trials, you can manage expectations and make
the right choice for your market.

1. Provide a number of test images jobs that are typical of the type of work and
application you intend to use the digital system for.
2. Test the same job on a selection of substrates for print quality comparison.
3. Check ink usage and cost (bear in mind that ink costs are much higher than
analogue printing).
4. Confirm if substrates are specially coated and confirm costs.
5. Hidden charges - are there any click charges (some systems make a charge
per print), or monthly service charges?
6. Are there any monthly service and maintenance charges to take into
consideration?
7. Do you need to purchase any additional software packages or computer
hardware?
8. The future - is the system about to be superseded by a new model?
9. What is the ongoing support for this equipment and end-of-life period for
parts?
10. Ask the right questions, listen carefully and read between the lines.

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HOW MANY COLOURS:

Typical systems offer mono or a
minimum of 4 process colours.
A combination of these process
colours can produce a wide
range of colours and effects. But
the colour gamut range is limited
and, to some degree, colours are
transparent, thus affected by the substrate colour. In order to achieve specific
pantone colours outside the normal gamut some manufacturers provide 7-8
colours to increase the colour range and allow adjustment according to substrate
colour, while other manufacturers offer a separate white head to provide a
substrate block or base to apply CMYK. A hybrid system of Digital/Flexo
technologies can provide close to 100% colour gamut.

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COLOUR MANAGEMENT SOFTWARE

Taking your image file and turning it into a high-quality printed web is the most
vital part of your new print engine. Most systems come with a standard colour
management software package, and these can be very basic or difficult to
navigate, or at worse not provide the best results on your system. More intuitive
add-on packages focused on labels may prove worthy of consideration. Suites of
modules and packages can be tailored to your application, but can be expensive
and often require an annual fee for a user licence. The advantage is you will
always have the latest user-friendly version, and the latest advances in digital
print processing to optimise output and production.

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WORKFLOW SOFTWARE:
Software to plan workflow and production has been available for many years,
but has progressed to include digital and hybrid production processes.
Managing job workflow to optimise production schedules is key to getting the
best out of your conventional and digital print production. The ability to group
jobs according to printing method, material choice, colours, and tooling will
improve efficiency, productivity and profit margins. New jobs can optimised at
the start of preparation and reprographics stage, screening for a particular
press or system, eliminating the need to make unregulated changes in the print
shop and, in turn, reducing duplication and waste.
LABELS AND PACKAGING PRINTING

OFFLINE FINISHING:
Separate finishing equipment has been available for the past 20 years, using
servo technology in semi and full rotary equipment to provide good register
between pre-printed substrates and the desired cutting lines. Flexible Cutting Dies
are the tool of choice to minimise cost and are easy to change forms with
minimum disruption. Optional finishing systems like embossing, hot foil, cold foil,
over varnishing and spot varnishing are readily available to add value and
creativity.

Digital Print Engine plus Offline Finishing

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PRINT EMBELLISHMENT:
A buzz word in the Print industry is
‘embellishment’. This can take the
form of embossing, spot varnish
effects, tactile, raised print, 3D
effects and braille. Often this is
achieved with a mixture of analogue
techniques such as physical
embossing and silk screen, which do
not lend themselves to short runs
associated with digital printing. In
recent years, ink jet has seen growth in this area where special heads can deposit
high volumes of varnish to achieve the effects. Because of its flexibility, you can
add these embellishments inline on selected digital production presses, or offline
using dedicated print enhancement solution. Amongst others, Konica Minolta
have been leading progress in this technology, allowing you to produce ultra-
precise spot coatings, highlight defined areas and add 3D effects to preprinted
digital , flexo or offset originals in long or short runs. Digital print embellishment
enables you to create sensory artwork using a range of different finishes. That will
help you to be creative and enhance your print products and give your customers
a better brand experience.

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HYBRID COMBINATION TECHNOLOGY:

With relatively slow production speeds, digital printing and finishing are regarded
as separate processes. With current speeds of some digital technologies
approaching speeds of analogue flexo, offset and letterpress machinery, it is
becoming practical to combine digital printing with traditional print shop
equipment to take advantage of ‘in line’ finishing, cold foil, hot foil and silk screen
services in order to enhance and add value to the product label - hence the term
‘hybrid digital solution’. A hybrid solution can bridge the gap between flexo and
digital for a print shop and can improve the colour gamut limitations of digital.
Thanks to its flexibility and ongoing ability to interchange print technologies, you
can produce labels in either flexo or digital print, or a combination of both
technologies; this is the significant long-term advantage of a hybrid press.

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IN LINE COMBINATION PRINTING:

With print speeds of up to 120Mts per minute of single pass digital systems like
UV ink jet it has become perfectly practical to combine analogue and digital
systems into a single press. A perfect example is adding variable information such
as bar codes and sequential numbering onto generic labels or security labelling
applications. Another application might be personalisation of generic labels for an
advertising or promotional campaign. Additional opportunities to add value such
as embossing, hot foil, cold foil, over varnishing and spot varnishing are readily
available with in-line hybrid systems.

IS A HYBRID SOLUTION RIGHT FOR ME?:

This will depend on the structure of your production workflow and the quantity of short run
jobs that will benefit from combining printing processes and finishing lines. Some will point out
that investment in a hybrid press will be higher, which actually may not be the case.
Furthermore, a hybrid system provides the option to switch from one technology to another to
improve your return on investment.

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Focus have long-standing experience integrating digital print systems into its
existing servo-based machine lines, from mono to full colour systems. The current
dFlex systems are found in applications for security bar coding, variable data,
tamper evident labels, personalised labels and general short run printing
applications. The advantage and ability to switch to normal production is a real
advantage to maximise production capacity. We recognise that maximised use of
the equipment needs to be realised to reach an acceptable return on investment
for all levels of business.

If you want to find out more information about the dflex machine click here or if
you want to find out more about the dpack machine click here.

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ATTRACTING NEW CUSTOMERS AND

EMPLOYEES:
We hope this guide gives you a flavour of digital technology and what it can bring
to your business. Having looked at press types, there is no doubt equal
consideration will be required to manage front end graphics, workflow,
production management and marketing. With careful investment, you can
complement your production selection for the benefit of your clients, adding new
accounts, value and profit to your bottom line.
It is often overlooked how new technology can revitalise your staffing
opportunities. Investment in digital technology across your business will attract
younger staff who are more receptive and computer literate, and savvy about
marketing. Digital technology is an opportunity to bring forward a new generation
of staff to your business who are eager and fast to learn.

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Email: admin@focuslabel.com

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