Printing press operator skills
Labour often accounts for the most significant proportion of a converter’s total operating costs. Indeed, recent interest rate increases and inflation have made wage pressures the top business concern for 71% of printing service providers surveyed in the BPIF Printing Outlook Q1 2025.
In addition, skills shortages in the print industry have increased the costs of hiring skilled professionals experienced in setting up flexo technology and have also presented challenges in finding personnel with the correct skills.
By comparison, many converters find recruiting operatives to run their digital printing and finishing equipment easier. Digital printing technology is typically much easier to run than traditional flexo technology, and technologically savvy candidates often find it easy to adapt with minimal training needed.
Issues in recruiting suitable staff are driving a change in mindset in the industry, with converters that might not have the local labour required to run another flexo line turning instead to digital technology.
Indeed, one quarter of the respondents in the BPIF survey are planning to invest in digital technology in 2025, while half of respondents are investigating automation and workflow improvements that could help them mitigate labour shortages and enhance efficiency.
Print workflow management
Once a converter has decided to invest in digital printing technology, particularly where the digital asset will increase printing speed, it is important to consider all steps involved in creating the finished label to determine which digital roll-to-roll or hybrid press will deliver the best results.
While a new hybrid printing and finishing line will typically deliver a process where all elements work together with optimum performance, adding a digital roll-to-roll press to an existing multi-step process is more complex, requiring a closer look at the complete label production workflow.
A multi-step process could include several pieces of upstream and downstream equipment connected by manual handling processes. While upstream converting equipment can typically maintain a constant supply of prepared substrate to a label press, downstream equipment could cause bottlenecks, lowering productivity and reducing the return on investment. Converters looking to take advantage of higher press speeds should ensure that finishing equipment always matches or exceeds the production speed of the label press, maximising the number of finished labels produced.
Converters purchasing a high-speed press should also be confident that they will be able to generate the orders needed to make use of the additional capacity – as a press that is underutilised will not be able to deliver the desired return on investment. This can also be an issue in digital hybrid label printing processes, where integrated digital print engines – the most significant investment in the line – can be subject to considerable periods of downtime during flexo-station set-up. Where suitable offline finishing equipment and personnel are available, a roll-to-roll press could be the more efficient choice, delivering a faster payback thanks to near-continuous production and offline finishing.
Conclusion
Converters investing in a new digital label printing press need to consider the bigger picture, focusing on the overall value a press could deliver to their business as well as the initial investment, consumable cost, or press speed.
A digital printing press supplier offering reliable solutions, backed by a service offering tailored to a converter’s needs, will be a strong partner that can support converters in scaling their business and maximising the return on their investment.
Keep an eye on the bigger picture and ask about the Domino total cost of ownership calculator! Our Digital Solutions Programme team will be happy to assist.
Just-in-Time Printing
According to FINAT, the primary driver behind brand requests for digital printing is the need for shorter print runs, with demand increasing as brands focus on reducing waste and meeting sustainability targets through just-in-time production.
Digital printing’s ability to handle short runs with quick turnaround times removes the need for brands to place large label orders that risk obsolescence and excess stock. Discussions with brand owners indicate that over 30% of printed labels are often discarded due to regulatory or ingredient changes, rendering existing designs outdated and requiring fresh print runs with updated information.
Just-in-time label production using digital printing technology allows brands to print only what they need, when they need it, making it easier to respond to label changes while reducing waste.
From both a financial and sustainability perspective, digital printing offers advantages. Although placing frequent short-run orders at a higher unit price may seem costly, brands can achieve overall savings if the total cost of digitally printed labels remains lower than the value of labels that would otherwise be wasted. In this context, a higher price per label can be justified.
Additionally, just-in-time printing enables converters to maximise the use of their digital printing assets, responding quickly to increasing demand for short-run jobs while strengthening customer relationships through flexible, on-demand delivery.
Digital presses also provide added value by fulfilling brands’ variable data printing needs. They will play a crucial role in meeting the rising demand for variable 2D codes as brands prepare for Sunrise 2027, integrating promotional, supply chain, and point-of-sale data into GS1-powered QR codes.
Press Downtime
Time is money, and maximising press uptime is crucial for converters looking to optimise daily label production and maximise their return on investment. Any period of machine downtime can be a significant setback.
Compared to analogue technology, digital presses require minimal set-up. Real-time, inline image processing enabled by digital technology helps minimise downtime and enhance productivity, with efficient job preparation via the DFE. Unlike flexo printing, digital printing eliminates the need for plate creation, reduces mechanical set-up time, and allows for easy production schedule adjustments to accommodate short-notice jobs.
Flexo press set-up, by contrast, can be time-intensive. Each job changeover requires mechanical adjustments and increases consumable usage, as ink and material are wasted during set-up to ensure print quality, colour accuracy, and registration.
For flexo converters handling a diverse range of jobs, changeover time can sometimes exceed the actual printing time, making set-up efficiency more critical than press speed in determining overall productivity.
Converters using both digital and flexo technologies understand that the best results come from using them as complementary solutions. Digital printing is a powerful tool for increasing the efficiency and profitability of existing flexo assets, freeing up flexo presses to focus on longer, more profitable runs while enabling new opportunities for short-run jobs.
Printing Press Operator Skills
Labour costs represent one of the largest operational expenses for converters. Rising interest rates and inflation have further exacerbated wage pressures, with 71% of printing service providers surveyed in the BPIF Printing Outlook Q1 2025 citing wages as their top business concern.
Additionally, a shortage of skilled professionals in the print industry has increased the cost of hiring experienced flexo press operators, making recruitment more challenging.
In contrast, many converters find it easier to recruit operatives for digital printing and finishing equipment. Digital printing technology is generally more intuitive to operate than traditional flexo presses, and candidates with technological expertise can often adapt with minimal training.
These recruitment challenges are shifting industry perspectives, with some converters opting for digital technology due to a lack of available labour to support another flexo press line. This trend is reflected in the BPIF survey, where a quarter of respondents plan to invest in digital technology in 2025, while half are exploring automation and workflow improvements to address labour shortages and enhance efficiency.
Print Workflow Management
When investing in digital printing technology—particularly where it increases print speed—it is essential to evaluate the entire label production process to determine whether a digital roll-to-roll or hybrid press will provide the best results.
A hybrid printing and finishing line offers seamless integration of processes for optimal performance. However, adding a digital roll-to-roll press to an existing multi-step workflow introduces complexities, requiring careful assessment of the entire label production system.
Multi-step workflows often involve several upstream and downstream equipment stages, with manual handling processes connecting them. While upstream converting equipment can generally maintain a steady supply of prepared substrates to a label press, downstream finishing equipment can create bottlenecks, reducing overall productivity and return on investment. To maximise efficiency, converters investing in high-speed digital presses should ensure that their finishing equipment matches or exceeds press speed, optimising output.
Additionally, converters must ensure they can generate sufficient order volumes to utilise the additional press capacity effectively. An underutilised press cannot deliver the expected return on investment, a challenge that also applies to digital hybrid printing processes. Integrated digital print engines—typically the most significant investment—can experience extended downtime during flexo station set-up. In such cases, a roll-to-roll press, supported by suitable offline finishing equipment and staff, may offer a more efficient solution, ensuring near-continuous production and faster payback.
Conclusion
When investing in a digital label press, converters should take a holistic approach, considering the overall value a press can deliver to their business rather than focusing solely on initial investment, consumable costs, or press speed.
A digital printing press supplier that provides reliable solutions, backed by a tailored service offering, will be a valuable partner in helping converters scale their business and maximise their return on investment.
