by Cassandra Balentine
The benefits of digital print continue to expand into labels. The technology makes variability, affordable short-runs down to one, and improved speed to market all possible. As label printing evolves, sustainability and flexibility are top priorities for converters worldwide.
Today, digital label systems are available in toner- and inkjet-based options, configured to meet volumes from entry to production.
Above: SnapPress’ LP-1 press is built to bring automation to shops that don’t have a robotics lab or a six-figure prepress department.
In addition to standalone digital devices, hybrid platforms integrate high-speed inkjet technology with traditional flexographic units. This configuration allows converters to produce short runs, variable data, and complex designs while incorporating inline finishing—all in a single pass. “By merging digital and flexography, printers can reduce waste, minimize setup times, and achieve exceptional print quality across diverse substrates,” shares James Thomas, head of sales and business development, Focus Label.
Moving Forward with Automation
Advantages of digital and hybrid label production add up with trends like automation, which enable print providers to produce jobs in minutes that once took hours to prepare—with no guesswork, no wasted material, and no “call the specialist” moments. “We like to say it’s automation that feels human—simple, intuitive, and margin-making,” shares Amanda Bacon-Davis, VP, ink and influence, SnapPress.
Across the industry, automation is a key differentiator in digital label production. “Modern presses are designed to reduce operator touch points, streamline job setup, and minimize waste. Automation now extends beyond print—encompassing prepress workflow, color management, and even post-press finishing. Integration with digital front ends (DFEs) enables automated job queuing, variable data handling, and consistent color output across devices,” explains Taylor Buckthorpe, director of sales and marketing, Colordyne Technologies.
Automation is taking shape in two forms—hardware and software.
Many digital label presses incorporate automation within the hardware of the printer. “Designed to enhance print quality and prolong the life of the printer, these features simplify maintenance and ensure it’s happening at regular intervals,” notes Mike Pruitt, senior product manager, professional imaging, Epson America, Inc.
Canon’s LabelStream LS2000 offers these elements while also helping to make a positive impact on sustainability goals. This is achieved through its water-based ink system and the reduction of materials typically required in the analog printing process, particularly for short- and medium-run length converting applications, shares Katsuhiro Matsufuji, VP, marketing strategy Unit, Canon U.S.A., Inc.
Calibration, profiling, and quality/inspection checks can now be performed inline with cameras and measuring devices at the touch of a button within the hardware. “This speeds up the printing device for label production substantially. The inline cameras and spectrophotometers provide important information such as whether or not the targeted color space is within tolerance and that no defects are present. This ensures quality and color-accurate labels are produced right after warming up,” shares Russell Doucette, product marketing manager, Konica Minolta.
John-Paul Burton, managing director, Eclipse Label Equipment, feels that it’s not so much about how the digital presses incorporate automation, but rather what automation is available to enhance production and reduce costs.
Within the solutions side, easy-to-use label imposition and hot folder management allow companies to streamline workflow into a drag-and-drop environment, simplifying prepress for both operators and customers. “Additional options such as preflight checks, template creation, embellishment/die plate creation, and web to print (W2P) storefronts can be added, simplifying the process further. Konica Minolta has helped perfect this for sheet-fed customers and the ability to migrate it to label customers is a welcomed addition,” says Doucette.
Juan Kim, CEO, Valloy Incorporated, sees a general trend towards end-to-end workflow automation that follows the general steps of W2P to RIP, preprint, process print, post-print/embellishment, and finishing. He says barcode/quick response (QR) code job calling, closed-loop color, substrate presets, predictive maintenance, and in/nearline finishing are also tools supported by workflow automation in a digital label environment.
Overall, automation improves process efficiency and reduces the labor intensity for the task of label production. “Due to its relative maturity, there are some great examples of digital label presses that have implemented a substantial amount of automation,” notes Paul Edwards, VP, digital division, INX International Ink Co.
Edwards explains that the implementation of all-in-one workflows allow a roll of label stock fed into a printer to exit as finished rolls of labels and ready to be put on a box or envelope. The process of label production can include printing processes as well as embellishments such as gloss effects, foils, and more through various finishing and converting processes like die cutting, laminating, coating, and matrix removal.
For example, the introduction of digital processes such as real-time quality inspection and workflow optimization can significantly enhance the automation and efficiency of the system, offers Edwards. “A good example of an all-in-one workflow is the SEI Laser Labelmaster. It offers high efficiency and provides digital label converting, as well as many automated processes including automatic workflow integration, missing label detection, motorized automatic slitting, and on-the-fly job changes—to name just a few.”
Industry Trends
Evolving market trends, shifting trade conditions, and tariff fluctuations are all driving factors towards digital label production, as brands seek greater flexibility to manage unstable product variations and order volumes.
“As businesses face increasing pressure from time, labor, and material costs, digital technology offers faster setup and cleanup, improved productivity, and shorter turnaround times. While still requiring specialized skills, digital printing can be learned quickly, allowing access to a broader labor pool than traditional analog processes. Additionally, automated maintenance and self-monitoring features reduce manual intervention, enabling operators to focus on workflow efficiency and print quality,” suggests Pruitt.
Bacon-Davis sees brands looking for more SKUs, faster turnarounds, and sustainable solutions without the setup costs of flexography. “The rise of ecommerce packaging, personalized branding, and on demand production is fueling the digital label boom. Add to that a new generation of buyers who want data-driven designs, variable content, and made-local agility, and digital becomes not just an advantage, but a necessity. The conversation isn’t ‘should we go digital?’ anymore. It’s ‘how fast can we get there?’”
Companies also want product to stand out more, and like to try new looks and approaches for different markets. “Digital embellishments on labels can provide this, and companies are beginning to take notice of it. Companies want to try new concepts and digital makes it much easier. The simplicity of digital technology and the ability to show a client three to six different versions of a new label, whether it be a simple two-dimensional spot varnish or a more complex, multiple-pass foil/varnish combo enables companies to test and create new ideas and products much easier,” shares Doucette.
From fully variable, personalized content through to interactive features such as QR codes, labels now have greater value as differentiators. “Brand owners are aware of the differentiation that can be achieved via the implementation of digital content. Short run and digital content has made the digital production process more valuable and is driving demand,” comments Edwards.
“Brands are introducing more product variations and personalized packaging, leading to a surge in SKUs. Digital printing supports on-demand production, reducing lead times and inventory costs compared to traditional flexographic methods. Consumers increasingly expect personalized products and packaging. Digital printing allows variable data printing for unique designs, QR codes, and event-specific labels, which is difficult with analog processes. Combining digital and flexographic printing is gaining traction for cost efficiency and flexibility,” echoes Thomas.
Converters remain under pressure to deliver shorter runs, faster turnarounds, and more SKUs than ever before. “Brands are shifting toward on-demand and versioned packaging, enabling regionalization, personalization, and just-in-time production to reduce inventory waste. Sustainability also plays a significant role. Digital eliminates plates, reduces setup waste, and supports data-driven batching for efficient material use,” says Buckthorpe.
Additionally, as inkjet technology continues to advance in the areas of speed, color gamut, as well as substrate versatility, converters find that digital print solutions can now handle a larger share of their traditional flexographic or offset work.
“At Colordyne, we see strong interest in hybrid and retrofit models, where converters maintain their flexo capabilities while adding full-color digital capability inline. This hybrid model gives converters flexibility without a complete process overhaul,” offers Buckthorpe.
The trend towards decreasing the average run length of a production job is a clear one, and impacts pretty much all packaging applications to some extent. “Having the ability to make money on the shorter run length jobs fits nicely with the ability of the digital printer to create short-run jobs efficiently, with ever-increasing automation and the ability to provide all kinds of embellishments in a single manufacturing line. To some extent, this driver also dovetails with the sustainability drive as the digital process provides less waste and a more efficient process,” says Edwards.
“Digital label production is following the same path that so many mechanical printing technologies have taken over the decades. From publishing to desktop publishing, from silk-screen printing to direct to garment and direct to film, and from analog plate-based commercial presses to modern inkjet and toner presses in the print shop,” notes Burton.
In each case, he says the shift is driven by the same core demands—faster turnaround times, short run and variable data capability, reduced setup and labor, customization and on demand production, and greater flexibility to pursue new products and new niches without capital investment. “And where brands once needed long runs and high volumes to justify plate and screen setups, they now need flexibility, versioning, and the ability to react to customer demands immediately. All of those motivations apply to both printing and finishing.”
Kim notices several digital capabilities serving trends towards digital label production. For shorter turnarounds and SKU proliferation, plate and die-less agility wins. For faster turnaround and on demand label output, web to label and same-day service is ideal. Mass customization and variable data print enables serialized and market-of-one labels. Wider media/flexible packaging with films and foils benefit from low-temperature fusing and broaden media compatibility. Sustainability and waste reduction is also achieved through digital without plates and dies as well as a focus on right-sized runs.
“We’re seeing increased adoption to digital with more of a focus on sustainability. Furthermore, intelligent automation capabilities that digital has to offer can help offset challenges in the traditional label market,” shares Matsufuji.
Best Practices
Moving to digital label production—whether from a traditional converting business or adding labels as a digital service offering to additional commercial business—should take into account several considerations.
Edwards feels that increasing the volume of jobs for short-run digital content requires a few strategies. “Implementing highly automated and efficient digital printers and workflows, providing a competitive product and pricing, and then highlighting the ability to do this to customers and brands is vitally important. A clear message must be communicated for the customers to understand the potential product opportunities.”
The second consideration is related to pure volume, rather than the volume of jobs itself. “It requires digital equipment with the capacity for efficient high-volume manufacture and a workflow to support it. This will provide the best and most economical product for the longer print runs. It also boils down to communicating the advantages of the digital product and implementation of the correct technology—or blend of technology—required to deliver it,” suggests Edwards.
Bacon-Davis suggests starting with the low-hanging fruit—repeat short runs, private labels, or variable data jobs that flexographic shops avoid. “Build success stories around them. Then, streamline your workflow with automated color management, built-in RIPs, and integrated finishing.”
Most importantly, educate your customers. “Once they understand that they can get ten designs for the price of one setup, they start rethinking how they order labels—and that’s when your volume grows naturally,” stresses Bacon-Davis.
Pruitt feels that when moving to digital technologies, its essential to know your customers and their priorities. If they are looking for the lowest print cost and have no need for artwork changes, or quick turnaround—then they might not be the best fit for digital. The best opportunities lie with customers who require versioning, design changes and regional labeling—all are key selling points and areas where digital printing provides clear advantages in speed, flexibility, and customization.
Modern digital printing brings great flexibility and easier setups. “A key factor is understanding the volume requirements when stepping into the digital world for the first time, the cost of digital printing can be a little higher than traditional, which matters when we are looking at those high supermarket volumes,” notes Burton.
Buckthorpe says that the most successful converters treat digital as an extension of their production ecosystem, not a standalone device. “This means automating job entry, proofing, and color management, and using data analytics to identify jobs ideally suited for digital—typically those with multiple SKUs, short runs, or frequent artwork changes.”
Standardizing file formats, color profiles, and substrates also accelerate digital throughput. “Many converters increase digital volume by offering flexible pricing models and educating customers about the benefits of digital—like faster lead times and versioned artwork. Customers can rapidly grow digital volume when they align internal workflows and customer expectations around speed, flexibility, and reduced waste,” adds Buckthorpe.
Finishing is another consideration. Kim says digital printers are getting faster, but the speed of digital finishers has been “an adventure.” He points out that while laser cutting is fast, the quality may not meet commercial labels, while knife cutters tend to be slow but give substrate-independent good quality. “Valloy overcomes disadvantages of knife cutters—speed and automation. Valloy’s digital finishers can run in high speed with automatic depth adjustment as well as automatic job change and head distance control between multiple cutting heads.”
Leveling Up Labels
Today’s digital label presses are getting smarter. “Automation is about confidence and control. From auto-webbing and intelligent job queuing to direct help desk links and remote monitoring, automation is making label production more seamless, consistent, and operator friendly,” concludes Bacon-Davis.
Read more on digital label printing advancements online at dpsmagazine.com, including a webinar on the topic.
Jan2026, DPS Magazine
