Digital printing

Cwl Group adds HP Indigo 200K

Akanksha Meena — Fri, 24 Oct 2025 04:25:50 +0000

Cwl Group has won HP’s Global Award - Top Flexible Packaging Strategic Account of HP Industry Print, in recognition of its outstanding performance, innovation, strong technical capabilities and quality service in digital flexible packaging. The group also invested in its second digital flexible packaging device, the HP Indigo 200K, further deepening its footprint in the sector.

The digital flexible packaging business is a core focus of Cwl Group. Frank Jia, deputy general manager of Cwl Group and general manager of its digital business division, stated: ‘As the company advances its business, the proportion of small orders continues to rise. Producing with traditional equipment not only incurs high costs but also results in low efficiency, which becomes a bottleneck restricting the company’s development.’

Its core business, coffee bags has been exported to over 70 countries and regions worldwide. Such items require high color precision and consistent quality, while the market also has a growing need for multi-version customized packaging. Against this backdrop of dual demands, the company has shifted its focus to digital printing equipment that balances efficiency, quality and customization.

The company started to pay attention to digital technology as early as eight years ago, including visiting HP Demonstration Center in Guangzhou and testing from other factories which have HP Indigo press, laying a solid foundation before their first HP Indigo press.

In April 2022, the company installed its first HP Indigo 25K. This device accurately meets core needs such as small-order production, short delivery cycles and personalized customization, while also officially kicking off the development of Cwl Group’s digital printing business.

While upgrading its hardware, the company has simultaneously advanced talent reserves by nurturing a professional digital printing technical team. Additionally, in response to customers’ diverse needs, the company provides customized flexible packaging to ensure each pouch accurately conveys the brand’s value and core philosophy.

The first HP Indigo device is now at full capacity. With the new HP Indigo 200K, Cwl Group will further shorten delivery cycles and speed up responses. Internally, it cuts labor, energy and consumable costs via better automation and speed. Its strong variable design and printing capabilities meets multi-SKU custom needs, supporting Cwl’s to strengthen its high-value flexible packaging offering.

Slated for December production, the HP Indigo 200K will double Cwl’s capacity, handling both large-batch standard and small-batch custom orders. It also trims delivery cycles by 40 percent (via cloud connectivity/intelligent QA) and meets ‘same-day confirmation, next-day production’ for spot color orders.

Posted date

2 days 23 hours ago

Short title

Cwl Group adds HP Indigo 200K

Short summary

The new HP Indigo 200K will double Cwl’s capacity, handling both long and short-run custom orders.

First paragraph

The new HP Indigo 200K will double Cwl’s capacity, handling both long and short-run custom orders.

Regions

Asia-Pacific

Other topics

Installations

Related suppliers

Rate

Top story

Article main topic

Digital printing

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

Repacorp sees increased efficiency with new Xeikon press

Selah Zighelboim — Wed, 22 Oct 2025 20:45:40 +0000

Repacorp installed a Xeikon PX3300HD digital press at its Arizona facility earlier this year, with the goal of achieving greater consistency and crisper type print. Days after installation, the press was up and running, and three months later, the Repacorp team reports that the press has led to greater consistency in quality and faster turnaround times.

Aaron Dumke, vice president of packaging at Repacorp, and Bo Soto, plant manager at Repacorp’s Arizona facility, shared their experience with the digital press during a Xeikon event called ‘Unboxed: A Xeikon Learning Experience'.

Repacorp is a 50-year-old company with facilities in Ohio, Wisconsin and Arizona. Dumke described the Arizona facility as Repacorp’s ‘Amazon’ site, an all-digital press facility where the goal is to deliver fast turnaround times for customers.

The converter has had positive experiences investing in Xeikon presses in the past. In particular, Dumke and Soto extolled Xeikon’s customer service. Those positive experiences, combined with an interest in upgrading quality with Xeikon’s new Xerox printheads, motivated the company to purchase this PX3300HD.

The new Xeikon press replaced an older Panther machine. The Repacorp team says that setup and maintenance times have been cut in half with the new press, resulting in time and cost savings.

'Now, we can run at 70 m/min without having to worry about the quality changing an iota,’ Soto said. ‘We have that confidence.’

Posted date

4 days 7 hours ago

Short title

Repacorp sees increased efficiency with new Xeikon press

Short summary

The converter shared its experience with the PX3300HD press at a recent Xeikon event.

First paragraph

The converter shared its experience with the PX3300HD press at a recent Xeikon event.

Regions

North America

Other topics

Installations

Related suppliers

Xeikon

Rate

Top story

Article main topic

Digital printing

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

HP and Syntax open Digital Innovation Center in China

Selah Zighelboim — Wed, 22 Oct 2025 14:06:25 +0000

HP has partnered with its Chinese distributor Syntax to officially open a new Digital Innovation Center at Weikang Technology Innovation Park in Panyu District, Guangzhou, China. Spanning 1,500 sqm, the center is equipped with HP Indigo 6K, Indigo 200K and other PWI digital printing systems. It will enhance localized services, including on-site demonstrations, technical training and sample proofing, to better support the region’s label and flexible packaging industries.

Haim Levit, senior vice president and division president of HP Industrial Print, emphasized the center’s strategic significance during the opening ceremony. 'This 1,500 sqm facility is more than just a facility; it embodies our shared vision for the future of digital printing in China — a future fueled by innovation, collaboration and sustainable growth,' he stated. 'Since HP Indigo entered the Chinese market in 2002, we have partnered closely with local players to drive the digital transformation of the label and flexible packaging sector, redefining how brands, converters and printers engage with their customers. Our success stems entirely from the trust and support of our customers and partners, whom we deeply value.'

Jonathan Liu, president of Syntax, highlighted the impact of HP’s technology on the industry. 'The global installed base of HP digital printing equipment has now surpassed 9,000 units,' he noted. 'This technology not only addresses core demands like short-run production, customization and rapid delivery but also delivers unique added value — such as 3D printing capabilities — that traditional printing cannot match, effectively meeting the emotional and experiential needs of the new generation of consumers. As a long-term partner of HP Indigo/PWI in China, Syntax will continue to deepen our focus on digital printing application scenarios and help local customers capitalize on the opportunities brought by technological advancement.'

During the sharing session, representatives from HP Indigo, Factory18, Hybrid Software and Kurz Scribos delivered themed speeches, offering insights to help attendees achieve digital transformation across different links of the industry chain.

In a demo session, more than 100 guests witnessed on-site demonstrations of the HP Indigo 6K and Indigo 200K. Engineers provided detailed explanations of functions, such as printing principles, performance and color management.

The live demonstrations laid a solid foundation for on-site cooperation: four label converters and two flexible packaging printers signed contracts during the event. Notably, Fly Digital, a subsidiary of CWL Packaging, purchased its second HP Indigo flexible packaging press. Meanwhile, Shenzhen Shunxinchang invested in its fifth HP label digital press, underscoring its confidence in HP digital technology.

Looking ahead, HP will showcase its latest Indigo 6K+ equipment for the first time at Labelexpo Asia 2025. At the expo’s Sustainable Digital Pouch Factory zone, the Indigo 200K will work in intelligent synergy with Sinomech DigiLam solvent-free laminators and King-Mo KMM-600TSZ bag-making machines, presenting a complete end-to-end digital production chain for pouch manufacturing, from pre-press processing and printing to lamination and final pouch making.

Posted date

4 days 13 hours ago

Short title

HP and Syntax open Digital Innovation Center in China

Short summary

The center will enhance support for the region’s label and flexible packaging industries.

First paragraph

The center will enhance support for the region’s label and flexible packaging industries.

Regions

Asia-Pacific

Other topics

Associations, events & awards

Related suppliers

Rate

Top story

Article main topic

Digital printing

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

Xeikon showcases digital embellishment capabilities

Selah Zighelboim — Tue, 21 Oct 2025 00:03:00 +0000

Digital printing 20 October 2025

Xeikon showcases digital embellishment capabilities

At an open house at its Global Innovation Center in Elgin, Illinois, Xeikon demonstrated how its TX500 press integrates in-line with Kurz’s digital metallization technology.

Xeikon hosted an open house at its North American headquarters and Global Innovation Center in Elgin, Illinois, on June 9, just one day before the Amplify Print 2025 finishing and embellishment show in nearby Rosemont.

Xeikon used the proximity to the Amplify event to demonstrate its technology to converters, partners and other interested parties, who could visit at their convenience, examine the machinery in the demo room and converse with Xeikon team members.

A setup in the demo room showcased Xeikon’s digital embellishment capabilities, with Xeikon’s TX500 press integrated with a Kurz module for in-line, food-safe digital metallization.

‘This is really kind of a launch for this year,’ said Kent Wolford, Xeikon’s marketing director labels North America. ‘We’ve introduced the Titon [toner] but not the Kurz formally.’

Open house

The open house began with a presentation by Rob Welford, Xeikon’s president, and Wolford. After the presentation, attendees moved to the demo floor, where they saw Xeikon’s PX3300HD Panther LED inkjet press, as well as the in-line digital metallization performed with Xeikon’s TX500 press and Kurz technology.

Welford began the presentation by discussing Xeikon’s financial performance. Despite the uncertainty caused by US tariffs, Xeikon is doing well and has seen an increase in demand for toner this year, while ink sales remained stable, Welford said.

Wolford provided a history of Xeikon, which began more than 35 years ago in the dry toner technology field. Flint Group acquired the company in 2015. Seven years ago, it entered the inkjet market and quickly grew by acquiring Jetrion. Xeikon continues to support Jetrion presses, while introducing its own. Xeikon’s PX UV inkjet press is now in its third generation, the PX 3300HD.

Wolford highlighted how Xeikon’s technology has been proven to be food-safe and compliant with FDA and Swiss Ordinance regulations.

He also noted Xeikon’s focus on sustainability. The company’s inks are suitable for recycling and are made from recycled content. Additionally, the toner manufacturing plant is 100 percent powered by green electricity.

‘It’s not just the technology,’ Wolford said. ‘As a company, we’re very focused on the environment and being sustainable, even with our manufacturing facilities.’

Titon toner

The open house showcased Xeikon’s Titon toners. These dry toners are more durable and heat-resistant than Xeikon’s traditional toners, making them suitable for UV curing, according to the company. The toners can also print on a wide variety of substrates and are food safe.

‘There’s actually a photo initiator in this toner that makes it
more durable,’ Wolford said. ‘That toner, when it’s secured, when it’s sealed, it’s going to stay there. It’s not going anywhere.’

Xeikon’s website lists its potential uses in producing wine labels that don’t require varnishing and paper-based flexible packaging that doesn’t require an additional functional barrier for food safety.

Digital embellishment

Titon toners run on Xeikon’s TX500, a crucial component of the digital in-line metallization collaboration with Kurz. The two companies brought this demonstration to Labelexpo Europe 2025 in Barcelona.

The TX500 is a 20in roll-to-roll digital press, capable of running at 98 ft/min (30 m/min) and 1,200 DPI. Compared to previous models, it has additional automation in its registration and inspection technology.

For the in-line metallization application, the press uses Xeikon’s traditional toner for the metallic elements, in addition to the Titon toner. Unlike the Titon toner, the traditional toner melts in the curing process, adhering to the metallization components. The label designer has full creative control over the metallized components that can be included in the final product.

Wolford explained: ‘You’re still going to get that 1,200 x 1,200 sharp resolution, sharp detail, sharp edges capability, fine text in an in-line finished product.’

The uses for this metallization go beyond wine and spirit labels. Embellishment can add value for other end-markets and serve as an anti-counterfeit security measure. This setup enables variable printing, including for the metallized components. Xeikon’s target prospects for this application include label converters, flexible packaging converters, wall deco printers and more.

‘Every label can be different, even with metallization,’ Wolford concluded.

Edit content

Selah Zighelboim

North American Editor

Article Also Filed in:

Top story

Related magazine Issue

Jul - Sep 2025

Bobst unveils FlexJet module for digital label production

Piotr Wnuk — Mon, 20 Oct 2025 01:04:32 +0000

Bobst has introduced its FlexJet module, a digital printing system that enables single-pass production of extended content labels when integrated into a Bobst Digital Master press.

Unveiled at Labelexpo Europe 2025, FlexJet allows converters to produce multilayer formats and complex applications digitally in a single pass. The module also enables digital glue-side or liner-side printing, making short runs more profitable.

The new module is available for the Digital Master 340 and 510 platforms, expanding application offering and boosting productivity for label converters. It is claimed to be an industry-first Pure Digital Multilayer technology featuring multiple Digital Print Units working in-line. This fully integrated workflow enables single-pass production of complex label jobs such as multilayer, glue- and back-side printing.

‘We’re seeing significant growth in the demand for multilayer applications driven by a large number of factors – sustainability and regulatory requirements, including product information, nutritional values, and warnings in multiple languages, or for adding promotional content and interactive features,’ said Patrick Graber, marketing director for PL labels at Bobst. ‘Bobst already provides innovative solutions for producing multilayer labels using in-line flexo, all-in-one machines, and now a fully digital solution with FlexJet, which pushes digital printing beyond its traditional limits.’

The new FlexJet module, equipped with one black printbar, is powered by Bobst Inkjet Technology. It delivers a 1,200 x 1,200 DPI resolution at full process speed, thanks to Fujifilm Dimatix Samba printhead technology. This enables converters to print independently on the front, back, liner, or adhesive surfaces, all in a single pass, in-line.

Compared to conventional multi-pass production, FlexJet delivers 60 percent start-up time savings, 30 percent waste reduction, and double the output, according to Bobst. The performance metrics are based on simulated workflows for a 2,000 linear meter job with one SKU.

A Digital Master series platform with FlexJet allows converters to meet brand owner demands for enhanced traceability and consumer engagement while offering regulation-compliant labels.

Slovakian converter Litograf has invested in the Digital Master 340 with the Bobst FlexJet module to expand its multilayer product offering. According to Eduard Vidra, general manager at Litograf, the investment will result in a 100 percent increase in production capacity and profit margins up to 25 percent higher for certain applications.

'The investment will enable the company to accelerate growth and meet rising customer demand,' Vidra added.

Posted date

1 week ago

Short title

Bobst unveils FlexJet module for digital label production

Short summary

Single-pass digital printing module targets multilayer label growth.

First paragraph

Single-pass digital printing module targets multilayer label growth.

Regions

Europe

Other topics

New products

Related suppliers

Bobst

Rate

Top story

Article main topic

Digital printing

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

HP and MoviĜo Robotics unveil mobile robot for print production

Piotr Wnuk — Wed, 15 Oct 2025 22:30:01 +0000

HP and MoviĜo Robotics have launched the Ŝharko5 Hammerhead autonomous mobile robot, designed to transport carts and trolleys across print production floors, with Cewe Germany becoming the first customer to deploy the system.

The Ŝharko5 Hammerhead features one custom-sized fork and is built on the MoviĜo Robotics platform technology that was introduced in June 2024 with the Ŝharko5HP B2 Pallet robot. The modular design allows print shops to equip the robot with customized forks to fit various types of trolleys and roll containers.

The robot can be deployed as part of the INDI system, which is designed to communicate with HP Indigo presses and integrate press and robot operations. The combined technology handles transportation throughout print facilities, reducing manual labor and streamlining workflow while keeping presses continuously operational.

'We saw how we could benefit from automating certain cycles in our production logistics processes in our facility,' Frank Schulz, technical lead at Cewe Germany, explained. 'Working with HP and MoviĜo Robotics led to a plan for deploying the new Ŝharko5 Hammerhead in a fully automated process of moving our trolleys and pallets through production.'

Diego Diaz, global product manager of autonomous press and robotics at HP Indigo, noted that the Ŝharko5 Hammerhead fills the gap of moving materials across the production floor on carriers other than pallets, such as carts, trolleys and roll containers.

'We aim to offer the print industry a complete approach for production logistics, where mobile robots are integrated with presses and finishers,' Paul van der Hulst, CEO of MoviĜo Robotics, added. 'The system is managed from one control platform that is set up to support the customers' own business processes.'

Posted date

1 week 4 days ago

Short title

HP and MoviĜo Robotics unveil mobile robot for print production

Short summary

The Ŝharko5 Hammerhead autonomous system launches at the Cewe Germany facility.

First paragraph

The Ŝharko5 Hammerhead autonomous system launches at the Cewe Germany facility.

Regions

Europe

Other topics

Digital printing

Related suppliers

Rate

Top story

Article main topic

Ancillary equipment

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

Konica Minolta partners with Adobe on print embellishment technology

Piotr Wnuk — Wed, 15 Oct 2025 22:12:35 +0000

Konica Minolta has partnered with Adobe to integrate its new pre-press embellishment technology, Project Goldsmith, across the company's range of digital embellishment devices, marking the first implementation of the automated workflow system in the inkjet and foil embellishment space.

The technology aims to simplify the process of adding special finishes like foiling and varnishing to printed materials by automating job preparation and creating production-ready files, reducing errors and manual workarounds between designers and print service providers.

Project Goldsmith will be available across Konica Minolta's full range of embellishment devices, including the AccurioShine 3600 with iFoil One option, JETvarnish 3D 52L, JETvarnish 3D Evolution, JETvarnish 3D Web 400 and AlphaJET.

'We are excited to collaborate with Adobe to elevate and streamline the creative process for designers and the print professionals who bring their embellished visions to life,' Frank Mallozzi, president of IPP at Konica Minolta, noted. 'This new offering underscores the fact that embellishment is no longer a niche but a mainstream expectation.'

The automated file preparation toolkit empowers operators to move from hours of manual preparation to minutes of automated execution, helping print service providers reduce costs and increase profitability.

'Konica Minolta shares in our vision to make it easier for brands to adopt embellishment, and theirs are some of the first devices we have integrated the technology with to facilitate special effects such as raised print, spot color and metallics,' Mike Scrutton, director of print technology and strategy at Adobe, commented.

Posted date

1 week 4 days ago

Short title

Konica Minolta partners with Adobe on print embellishment technology

Short summary

The collaboration brings an automated workflow system to digital embellishment equipment.

First paragraph

The collaboration brings an automated workflow system to digital embellishment equipment.

Other topics

Digital printing

New products

Related suppliers

Konica Minolta

Rate

Top story

Article main topic

Finishing & embellishment

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

Xaar launches new Versatex printbar

Akanksha Meena — Wed, 15 Oct 2025 11:41:03 +0000

Xaar has launched the latest evolution of Versatex, its high-performance digital inkjet printbar. Designed to expand digital capability across a wide range of analog print lines and converting machines, the new printbar meets the growing demand for label varnish, foil embellishment and braille.

Alongside high-quality printing of high-opacity whites at 85 per cent in a single pass, the Versatex’s compact, low-maintenance unit features an upgraded Ink Delivery System which increases the high laydown performance by doubling the High Build Print Mode headline speed. For example, jetting 100 microns can now be achieved at 50 meters per minute with the new Versatex, compared to 25 meters per minute previously.

Powered by Nitrox printheads, it can jet fluids with viscosities of up to 1000 centipoise at ambient temperature (around 100 cP at jetting temperature). The Versatex’s ability to achieve higher laydown at builds in excess of 200 microns delivers exceptional performance for demanding print effects such as varnish and cold foil embellishments, white flood fill, black variable data and digital personalization.

With Xaar’s High Creativity print mode and High Laydown Technology, customers can achieve laydowns from 15 to 100 microns in a single pass – ideal for delivering high-build gloss, spot varnish, and matte textures on premium labels across wine, spirits and cosmetics.

Thanks to the Versatex printbar’s brand new braille mode – with enhanced speed and high laydown capabilities – braille printing is now faster and more precisely defined. This is especially valuable as demand grows in markets like Spain, where legislation is currently being proposed for braille on FMCG packaging .

Versatex also includes an upgraded Meteor datapath, which improves flexibility and data rates while supporting a wide variety of digital and volume data workflows. This, combined with the increased speed and higher laydown performance, is enabling significant improvements for web based variable data black print applications.

Developed in response to customer feedback, the new Versatex offers enhanced configurability and easy integration in a compact, low-maintenance design. Now compatible with right-to-left press directions as well as left-to-right, it fits new builds or retrofits without compromising layout or productivity. With many finishing lines running from right-to-left, this new capability makes the Versatex relevant for virtually all installations.

Its on-press interface streamlines job setup and image adjustments, ideal for short runs and variable work. With minimal operator intervention required, Versatex delivers high uptime and consistent output, while its modular, space-saving design ensures seamless inline or offline integration into conventional presses and finishing lines.

With sustainability in mind, the Versatex printbar, when compared to screen printing, continues to offer shorter setup times and a higher utilization rate, resulting in small run jobs being completed faster, the company reported. In addition, the ability to jet higher volumes and viscosities of fluids – at higher speeds – improves the efficiency of print processes, reducing the need for multiple passes, delivering faster print speeds and cutting energy use and costs.

Tom Mooney, product manager at Xaar said: ‘The Versatex printbar delivers exactly what industrial converters and printers need. Whether it is meeting demand for braille and embellishments or driving greater productivity and value in label production – the greater speed, precision and versatility of our new printbar is bringing the many benefits of digital to analogue presses and converting lines.’

The new Versatex builds on the success of the original printbar, which was launched in 2023 and is available from a range of OEMs and distributors including Nilpeter and Jet Technologies.

Posted date

1 week 4 days ago

Short title

Xaar launches new Versatex printbar

Short summary

The new printbar is developed to meet the growing demand for digital premium labels and braille printing.

First paragraph

The new printbar is developed to meet the growing demand for digital premium labels and braille printing.

Regions

Europe

Other topics

New products

Rate

Top story

Article main topic

Digital printing

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

FlexON’s bold leap into digital printing with Gallus One

Piotr Wnuk — Fri, 10 Oct 2025 02:40:22 +0000

Digital printing 10 October 2025

FlexON’s bold leap into digital printing with Gallus One

From flexo specialists to digital innovators, the Czech converter demonstrates how a strategic investment in hybrid technology drives efficiency.

From flexo specialists to digital innovators, the Czech converter demonstrates how a strategic investment in hybrid technology drives efficiency and growth in an evolving label market.

For a company that began as a small label specialist in 1994, FlexON’s transformation into one of the Czech Republic’s leading self-adhesive label manufacturers represents a compelling story of technological evolution and strategic investment. What began as a modest printing operation founded by two partners has grown into a 60-employee enterprise with a 3,000 sqm production facility on the outskirts of Prague, driven by a philosophy of continuous technological advancement and customer-focused service.

The company now serves a diverse client base across multiple industries, with approximately 85 percent of production serving the domestic Czech market and the remaining 15 percent exported throughout the European Union. FlexON’s emphasis on quality, speed and staying ahead of the technological curve has positioned the company as industry leaders in a competitive landscape where adaptability is increasingly essential to success.

“As a previous enemy of digital technology, if someone had told me that I would have two powerful digital machines by 2024, I wouldn’t have believed it”

This commitment to innovation was further cemented in late 2024 with FlexON’s installation of a Gallus One digital press, a move that owner Martin Chaluš admits would have seemed unthinkable just a few years earlier.

‘As a previous enemy of digital technology, if someone had told me that I would have two powerful digital machines by 2024, I wouldn’t have believed it,’ he reflects. ‘But today, it’s clear that smart, connected printing is key.’

A history of firsts

FlexON’s relationship with Gallus stretches back many years. In 2008, it became the first in the country to install a Gallus RCS 330 press, setting a pattern for pioneering investments that would continue through the decades.

‘We’ve always believed in being early adopters of technology that can give us a competitive edge,’ Chaluš explains. ‘Being first means we can offer capabilities to our customers that others simply don’t have yet.’

The company’s growth trajectory has been closely tied to these strategic technological acquisitions. From its official establishment in 1994, FlexON expanded steadily, constructing its own production facilities in Vestec in 2003 and extending with another production hall in 2008, the same year it installed a Gallus RCS 330.

This expansion wasn’t merely about increasing square footage but creating a production environment optimized for efficiency and quality control. The company also obtained ISO 9001:2008 recertification in 2011, demonstrating its commitment to maintaining the highest standards of quality management throughout its growth phases.

The company’s willingness to embrace new technology reached another milestone in 2021 with the installation of a Gallus Labelfire 340, once again marking the first such installation in the Czech Republic. This hybrid digital press represented a significant shift in Chaluš’s thinking about digital printing technology.

‘Five years ago, I wouldn’t have bought this kind of machine, because at that time the quality wasn’t there yet,’ Chaluš says of the Gallus Labelfire. ‘Nonetheless, I went on, and now Gallus has digital machines where the quality meets the needs and demands of the market.’

The digital evolution continues

The successful integration of the Gallus Labelfire into FlexON’s production capabilities laid the groundwork for further digital expansion. By November 2024, the company was ready for its next significant investment: the installation of the Gallus One digital press, equipped with an additional flexo unit and a semi-rotary die-cutting module.

The Gallus One, launched in 2022, represents the latest in Gallus’s digital portfolio, featuring the System to Compose modularity concept. This approach allows converters to customize their press configuration based on specific market needs and production requirements. This level of flexibility aligns perfectly with FlexON’s diverse client base and varied label applications.

“We’ve always believed in being early adopters of technology that can give us a competitive edge. Being first means we can offer capabilities to our customers that others simply don’t have yet”

What makes this installation particularly notable is how quickly the press was put into production. According to Gallus Group, FlexON was printing customer jobs even during the operator training period, showcasing both the user-friendly nature of the technology and the company’s ability to rapidly adapt to new equipment.

‘The learning curve was surprisingly short,’ says Chaluš. ‘Our operators were already familiar with the Gallus ecosystem from our previous installations, which meant we could focus primarily on mastering the digital aspects rather than starting from scratch.’

In 2021, the company installed Gallus Labelfire 340, marking the first such installation in the Czech Republic

For Chaluš, the decision to invest in the Gallus One was driven by evolving market demands. ‘Given increasingly shorter orders and frequent changes in artwork, the importance of digital printing is growing, which is why we looked at installing a digital label press,’ he explains. ‘We’re seeing average run lengths decrease year after year, while the frequency of design updates continues to increase, particularly in the food and beverage sectors, which make up a significant portion of our business.’

The press’s custom configuration, with an additional flexo unit and die-cutting capabilities, has created significant production efficiencies. ‘The custom composition of this new solution means that we now have a finished label that “falls out” of the press needing only to be cut, saving us time, streamlining production and increasing profitability,’ notes Chaluš.

The impact on FlexON’s production capacity has been immediate and substantial. ‘The Gallus One has now replaced up to two of our conventional presses,’ Chaluš reports, a testament to the productivity gains achieved through digital technology.

The Gallus partnership

FlexON’s choice of Gallus technology for its digital transformation wasn’t made lightly. When discussing the 2021 Gallus Labelfire investment, Chaluš highlighted several factors that guided his decision-making process, considerations that likely influenced the subsequent Gallus One investment as well.

‘From the practical viewpoint, in the first place, I wanted a machine with a big corporation behind it,’ he explains. ‘Another reason was our good relationship with the Gallus and Heidelberg suppliers, which provide us with first-class support and service. Moreover, our mutual relationship long ago grew from mere business to a friendship.’

The design and integrated nature of Gallus’s digital technology also played a key role. ‘I really liked the design of the Gallus Labelfire, the integrity of the whole solution. It’s actually a hybrid machine combined with other technologies,’ Chaluš noted. ‘It’s great that just one printer can run the whole unit, and at the end comes a finished product, including refinements.’

These advantages appear to have carried through to the experience with the Gallus One. Dario Urbinati, CEO of Gallus Group, comments: ‘FlexON is a dynamic and thriving business, and we look forward to partnering and supporting its activities over the coming months and years.’

The business case for digital

The rapid return on investment expected from the Gallus One installation highlights the business case for digital technology in today’s label market. Gallus reports that FlexON has ‘seen significant success within just a few months of installation, with the presses already demonstrating promise of achieving ROI and breakeven within an impressive timeframe.’

This experience mirrors that of other early Gallus One adopters. US-based PrintFlex reported that the technology had significantly reduced its production costs, with CEO Liz Pecha-Poelker describing the investment as offering ‘the lowest total cost of ownership for digital label production.’

After extending its factory in 2008, FlexON invested in the Gallus RCS 330

For FlexON, conducting a thorough ROI analysis was essential before committing to such a significant investment. ‘We evaluated not just the upfront costs, but the total cost of ownership including consumables, maintenance and labor,’ Chaluš notes. ‘The calculations showed that for our specific mix of work, the Gallus One would provide substantial cost advantages compared to our conventional presses for runs under certain lengths.’

The advantages of digital printing extend beyond simple productivity gains. When discussing its earlier Gallus Labelfire installation, Chaluš emphasized the benefits of very short preparation times compared to conventional presses: ‘On conventional machines, preparation often takes much longer than printing itself. Preparing complex orders on the Gallus Labelfire takes about 10 minutes, and then you’re producing.’

He also noted particular advantages for orders with variable content but the same parameters: ‘This might involve labels in more than one language or labels where only the graphic varies. For Gallus Labelfire, these variations are one order with one preparation process. Then, the time savings are enormous. Not to mention savings on printing forms and start-up material.’

The elimination of printing plates represents a significant cost reduction, especially as material costs continue to rise across the industry. ‘Previously, we would need to create new plates for every design variation or color change,’ Chaluš explains. ‘With digital, those ongoing costs are eliminated, making even very short runs economically viable for both us and our customers.’

These same advantages apply to the Gallus One, with its digital workflow and rapid changeover capabilities, which are perfectly suited to the trend toward shorter run lengths and more frequent design changes that Chaluš has observed in the market.

A balanced approach

Despite its embrace of digital technology, FlexON maintains a balanced approach to its production capabilities. The company still operates both flexo and offset printing equipment, allowing it to match the production method to the specific requirements of each job.

‘Different technologies have different sweet spots,’ Chaluš explains. ‘For very long runs with minimal variations, flexo still makes economic sense. For mid-range runs with multiple variations or frequent design changes, digital becomes the clear choice. By maintaining capabilities across technologies, we can always choose the most efficient production method for each job.’

This philosophy echoes Chaluš’s current view of the industry: ‘Anyone who wants to stay in the market will need an appropriate combination of both digital and conventional technologies; it’s just a matter of proportion.’

“Anyone who wants to stay in the market will need an appropriate combination of both digital and conventional technologies; it’s just a matter of proportion”

This balanced approach also extends to its finishing capabilities. The Gallus One installation, with its integrated die-cutting module, allows for a finished product directly off the press, while still maintaining flexibility for more complex finishing operations when required.

The company’s production mix has evolved significantly since its founding. Where once long-run flexo jobs dominated its production schedule, today’s order board includes a much higher percentage of short to medium runs with faster turnaround requirements. The label market in the Czech Republic has followed global trends toward greater product personalization, regional variations and seasonal promotions, all of which favor digital production methods.

‘Today’s brand owners want flexibility,’ notes Chaluš. ‘They might need 10,000 labels today, then a quick revision for a product launch next week. Our conventional equipment simply couldn’t keep pace with these changing demands without significant cost implications. The Gallus One helps us say “yes” to these requests while maintaining healthy margins.’

Looking forward

With the Gallus One now fully operational, FlexON appears well-positioned for continued growth in the competitive Czech label market. The company’s history of technological leadership, coupled with its strategic approach to digital integration, suggests it will continue to evolve in response to changing market demands.

‘We are delighted to report the success of Gallus One customer in digital label printing: a powerful example of how our ongoing innovation efforts in this strategic growth segment are continuing to deliver transformative solutions to market and creating a meaningful real-world impact,’ comments Urbinati of Gallus Group.

The Gallus One technology itself continues to evolve, with Gallus showcasing an expanded version at drupa 2024 featuring a wider 430 mm print width and expanded color gamut for superior color fidelity. The company’s System to Compose modularity concept allows customers like FlexON to potentially upgrade and expand their press capabilities as new modules become available, future-proofing their investment against evolving market requirements.

For Chaluš and his team, the transformation from conventional print specialist to digital innovator represents not just a technological evolution but a fundamental shift in business strategy. Their willingness to embrace new technology, coupled with a practical approach to implementation, has positioned FlexON at the forefront of the Czech label industry.

‘The label industry never stands still,’ reflects Chaluš. ‘When we started in 1994, no one was talking about digital printing for labels. Now it’s becoming the dominant technology for many applications. Who knows what the next major technological shift will be? What I do know is that by maintaining our philosophy of quality, speed and technological progress, we’ll be ready to embrace whatever comes next.’

FlexON’s evolution mirrors broader industry trends toward more automated, connected and flexible production systems. The company has gradually shifted from being primarily a manufacturing operation to becoming a solutions provider, helping brand owners navigate the increasingly complex world of packaging decoration with expertise that spans both conventional and digital technologies.

As the label market continues to evolve toward shorter runs, faster turnaround times and more complex designs, FlexON’s investments in digital technology, particularly the Gallus One, appear well-aligned with these trends. For a company that has built its reputation on being first to adopt new technologies in its market, the Gallus One installation represents not just another ‘first,’ but a strategic positioning for future success.

With sustainability becoming increasingly important to brand owners, the reduced waste and energy consumption of digital production may provide further advantages.

Though Chaluš doesn’t specifically mention environmental benefits in his assessment of the Gallus One, the elimination of plates, reduced make-ready waste and more efficient production processes all contribute to a smaller environmental footprint, another factor likely to drive continued digital adoption across the industry.

Click here to find out more about FlexOn.

Article Also Filed in:

Top story

Article type

Features

Konica Minolta raises 300,000 USD for pediatric cancer research

Piotr Wnuk — Thu, 09 Oct 2025 22:39:35 +0000

Konica Minolta Business Solutions U.S.A. has raised 300,000 USD through its first company-led charity event, bringing together employees, dealer partners and vendors to support Hackensack Meridian Health Foundation's Tackle Kids Cancer program at Griffin & Howe at Hudson Farm in Andover, New Jersey.

The event took place during Childhood Cancer Awareness Month in September and marked the 10th anniversary of Tackle Kids Cancer. Proceeds will advance pediatric cancer research and patient care at Hackensack Meridian Health's two children's hospitals, Joseph M. Sanzari Children's Hospital in Hackensack, New Jersey and K. Hovnanian Children's Hospital in Neptune, New Jersey.

'At Konica Minolta, we know that true impact happens when people come together with passion and purpose,' Sam Errigo, president and CEO of Konica Minolta, stated. 'The 300,000 USD we raised for our very first company organized charity event reflects the heart of our employees, the generosity of our dealer network and vendor partners and the collective belief that every child deserves hope, healing and a future.'

The day featured clay shooting activities, raffles and a live auction, culminating in a collective donation presented to Hackensack Meridian Health Foundation. Eli Manning, TKC team captain and two-time Super Bowl champion, joined the celebration.

'To raise 300,000 USD in their very first year shows the depth of commitment from their employees, partners and leadership,' Joyce P. Hendricks, president and chief development officer at Hackensack Meridian Health Foundation, added. 'This generosity will help us expand clinical trials, provide critical resources and deliver compassionate care to the children and families who inspire us every day.'

Konica Minolta intends to make the event an annual tradition.

Posted date

2 weeks 3 days ago

Short title

Konica Minolta raises 300,000 USD for pediatric cancer research

Short summary

Inaugural charity event supports Hackensack Meridian Health Foundation program.

First paragraph

Inaugural charity event supports Hackensack Meridian Health Foundation program.

Regions

North America

Other topics

Digital printing

Related suppliers

Konica Minolta

Rate

Top story

Article main topic

Associations, events & awards

Redirected

Off

Moved to features

Off

Lead image:

New batch

Off

redirected

Off

Digital printing

Cwl Group adds HP Indigo 200K

Repacorp sees increased efficiency with new Xeikon press

HP and Syntax open Digital Innovation Center in China

Xeikon showcases digital embellishment capabilities

Open house

Titon toner

Digital embellishment

Selah Zighelboim

Share this

Stay up to date

Bobst unveils FlexJet module for digital label production

HP and MoviĜo Robotics unveil mobile robot for print production

Konica Minolta partners with Adobe on print embellishment technology

Xaar launches new Versatex printbar

FlexON’s bold leap into digital printing with Gallus One

Share this

Stay up to date

Konica Minolta raises 300,000 USD for pediatric cancer research