Automating Offset and Flexo Printing Operations

It’s no secret automation is transforming the landscape of flexo and offset printing operations for custom-printed labels and packaging. After all, by integrating cutting-edge technologies and streamlined processes, manufacturers are not only increasing efficiency and consistency but also enhancing the quality of their products.
Automation has improved by supporting higher run speeds, reducing changeover time, and allowing equipment to get wider. Equipment has also improved — supporting wider ranges of colors and reducing operator time spent matching colors. These are all key attributes companies consider when investing in printing.
Measurable Results
Jay Parks, senior vice president of operations, packaging and labels, for Chicago-based RRD, a global provider of packaging and print solutions, notes the company has integrated a great deal of automation throughout its flexo and offset printing operations in recent years.
“For offset, we are equipped with automated plate and coater changing, automatic ink dispensing on sheet-fed presses, and press quality inspection systems,” he says. “With flexo printing, we have added tools including turret rewinders, cobot palletization, and robots. Each of these tools helps to optimize our workflows, enabling us to work more efficiently and effectively to deliver the high-quality packaging and labels our clients expect.”
RRD measures efficiency and productivity through metrics such as throughput, delays and makeready time, and press utilization, and thanks to automation, it has seen significant improvements in each of these areas.
“This progress stresses the need for a continued focus on solutions that will help streamline our operations, especially as demand patterns and expectations become more stringent in an increasingly digital world,” Parks says.
Mike Murton, president of OMNI Systems, a custom label converter based in Cleveland, Ohio, which houses more than 65 flexo and digital printing presses up to 22" wide with up to 10 colors, says the company has maximized its production efficiency and capacity through automation. [Editor's Note: This article had previously listed OMNI Systems' headquarters as in Virginia. The converter is located in Cleveland, Ohio — not Virginia.]
“We are steadily expanding our equipment with investments in Martin splicers and ABG turrets to further increase uptime and output,” he says. “Once installed, the addition of a 26" press will be our widest yet, and a new digital hybrid press will further stretch our print capabilities in the prime label space as well. As a result of these investments, OMNI can operate most of its equipment with a single operator.”
OMNI tracks several KPIs to assess operational efficiency: average run hours per shift, speeds, scrap efficiency, and actual versus estimated performance.
“Our enterprise resource planning (ERP) systems play a key role in tracking real-time data, allowing us to monitor the impact of our waste management automation program,” Murton says. “Since the launch of the project in January 2024, we’ve seen notable improvements in scrap performance, run speeds, and overall production efficiency.”
Erick Nova, operations manager of Morgan Chaney, a Phoenix, Arizona, company that has in-house flexo printing and partners with leading manufacturers for offset and specialty printing, says automation is playing an increased role in creating high-quality, cost-effective packaging.
“Most of our automation happens on the back end,” he says. “This means less paperwork and more digital tracking. We use automated work orders, purchase orders for materials, and real-time ink inventory tracking to keep things running smoothly. It helps us waste less. Automated inventory tracking keeps us from over-ordering supplies, and smarter material usage reduces excess waste. While we still do a lot manually, these small efficiencies add up over time.”
Morgan Chaney has seen approximately a 10% improvement in order processing speed thanks to automation and the need for less manual entry and a faster turnaround. “Our key metrics are order processing time, ink inventory accuracy, and waste reduction,” Nova says. “While we’re still working on upgrading some processes, these small changes are making a noticeable impact.”
Michael Gebera, director of operations at Tapecon in Buffalo, New York, notes for certain products coming off its flexo lines, the company has integrated automated vision systems and automatic packaging solutions into its flexo printing operations. These technologies have significantly reduced labor needs and improved efficiency. For some packaging applications, one press operator is able to do work that previously would have required six employees.
“In another aspect less thought of, we have implemented cobots into our manufacturing processes that can take on the monotonous and repetitive tasks that not only aid in efficiency but also the health and ergonomics of our workers,” he says. “Our operators experience less workplace injury/wear and tear while also spending more time on specialized processes.”
Overall, the ROI for Tapecon after automating specific printing processes has been significant. Gebera says, “We have seen cost savings in direct labor and increased efficiency, which has contributed to predictable production outcomes.”
Supporting Customization
Automation has enabled companies to increase customization and personalization in their product offerings. For instance, RRD has seen automation support customization through RFID labels.
“With automation, we print RFID labels that can be directly inserted into boxes, supporting our clients to meet the increasing RFID retailer mandates, from Walmart and others,” Parks says. “By printing and incorporating these labels through a seamless process, we drastically cut down on the time traditionally required to print and apply the labels in separate operations. This type of customization is key for our clients, as they face retail requirements to track individual products throughout the entirety of the supply chain.” For Tapecon, automated technologies such as variable data printing and workflow automation have been critical in customization, Gebera says.
Overcoming Challenges
One of the biggest issues printing companies have when dealing with automation is integrating the tech with older systems. Implementing automation also comes with the challenges of technical maintenance, specified training, and increased ramp-up time.
“For ramp-up time, it can be difficult to apply new technologies while maintaining high levels of productivity and output, especially when an automation feature is connected directly to a press,” Parks says. “We have learned to plan accordingly for new installations, allowing plenty of time for startup and training on new technologies.”
Additionally, with more equipment comes more maintenance, requiring the right technical experts to ensure lines run smoothly.
The main challenge Tapecon faced was the high initial costs associated with implementing automation technologies. “To address this, we focused on high-volume and highly repetitive processes to ensure that the volume would compensate for the initial entry costs,” Gebera says. “Another challenge was ensuring that our operators adapted to the new technologies. We addressed this by providing comprehensive training and support.”
To ease the minds of workers worried about possibly losing work to automation, Murton says, OMNI has successfully instilled a mindset throughout the company that automation is here to support — not replace — jobs. “As automation grows, so does the complexity of the work,” he says. “This opens doors for advancement opportunities.”
Sustainable Mindset
To keep up with increasing sustainability demands in the packaging industry, many companies are finding automation contributes to more sustainable practices, such as waste reduction and energy efficiency.
“We have seen a dramatic decrease in product errors such as color inconsistency and ink smudging, particularly due to automated ink processes and heightened quality control checks,” Parks says. “With the ability to flag errors earlier in the production process, we avoid the need to reproduce — and potentially reship — products that do not meet our quality standards.”
Looking Ahead
There’s little doubt automation will continue to make a big difference in the months and years ahead, and printing companies believe its faster production and less manual work will be the game changers.
“We’re keeping an eye on automated color calibration, AI-driven print monitoring, and smarter prepress workflows,” Nova says. “These are all things that could cut setup times and improve print quality.”
Bonus Learning Opportunity:
Comprising more than 355,000 sq. ft. of show space and hosting more than 680 exhibitors, PRINTING United Expo 2025 will showcase live demonstrations of automation equipment in action in addition to the show’s educational program and networking opportunities to learn from the best converters in the package and label printing industry. Registration is open now for the Expo at printingunited.com

A graduate of the University of Miami, Keith Loria is a D.C.-based award-winning journalist who has been writing for major publications for close to 20 years on topics as diverse as healthcare, travel, and tech. He started his career with the Associated Press and has held high editorial positions at publications aimed at entertainment, sports, and technology.