Everything Inline at the Same Time

Open new markets. Find new opportunities. Transform traditional converting space.

Chart a new path—Combine high-resolution digital print with the flexibility of inline converting to maximize revenue generation.

What’s required? Installation of a smart, simple, streamlined press—one that’s hybrid at heart—featuring intelligent automation. Mark Andy brought that message to some 250 package printers gathered at its Warsaw, Poland demo center on June 1, and reiterated it at multiple open houses and virtual events held up to this day.

Serving as the inspiring chant: “Everything inline at the same time!” Elaborating on the point, members of the print community were encouraged to, “Optimize internal processes and business development strategies around your new technology; generate more work and revenue with less time, labor and waste.” Executive after executive stressed that, “Hybrid formats are gaining attraction,” then said, “They will be the future!”

Trendlines appear to support the claim. In 2021, Mark Andy delivered 78 hybrids worldwide, a record for the company in the label and narrow web flexible packaging converting space. That development itself sparked multiple comments:

• Tom Cavalco, EVP, stated, “Last year, Mark Andy celebrated its 75th anniversary. Right from the start, it focused on developing and manufacturing solutions that meet current and future requirements and expectations of the label market. Three Mark Andy hybrid solutions—from entry-level to high-end—combine digital and conventional printing with numerous converting and embellishment options”
• Lukasz Chruslinski, sales manager, Mark Andy Europe, added that the benefits of the hybrid concept have been widely appreciated by many label printers worldwide. “The share of hybrid equipment in our total press sales continues to grow, and we anticipate it will be higher again in 2022 as many new contracts are currently being processed, with many installations scheduled before the end of the year”
• Przemyslaw Polkowski, director, Mark Andy Poland, observed, “Development of digital technology and its implementation in printing solutions is an area that is increasingly innovative and future-oriented, especially in packaging and label printing”
• Phil Baldwin, sales manager, Mark Andy Europe, served as master of ceremonies at the live event and explained, “Our goal is to highlight the possibility of printing the same design on different presses using different technology, because we’ve been observing an increasing trend toward print standardization among our customers”

Modularity Is Key

The team decreed that it subscribes to this theory: “Having the right equipment that allows you to service a larger segment of the label market provides maximum profitability. Having the right partners by your side means the sky’s the limit.”

Hybrid offerings have common elements, based on all being built on the Evolution Series modular platform for inline decorating and converting. As such, the executives maintained that each option can be custom configured to enhance a plant’s efficiency, profitability and bottom-line results. Specifics cited follow:

• Maximum performance: A fully integrated digital hybrid solution means zero throughput compromise for inline decorating and converting—a gamechanger for profitability metrics, according to Mark Andy. Demonstrated registration performance, tangible waste savings and less material ensure a substantial impact on your bottom line
• Affordable productivity: An attractive investment level and low cost-to-print position is the ideal solution for converters interested in single-pass, production-level digital hybrid printing. With precise independent inking and impression, robust diecutting options and production responsive tension control, Mark Andy noted that high-quality labels and film are guaranteed. Fast changeovers and easy setup for print and die stations reduce downtime and increase daily capacity limits
• Future-proof options provide adaptability to grow with your investment through the flexibility provided by Evolution Series technology. This platform unlocks the hybrid at heart capabilities needed for success at any point in your business. Mark Andy pointed out that all machines are manufactured with every converter in mind, meaning they need only choose the options they need today, with a profitable path forward tomorrow through modularity. Plus, utilization of VDC-SR allows for pressroom efficiency by slashing changeover time by 80 percent, freeing up operator availability for increased throughput

Highlights of each model in the lineup, as briefed to actual printers, are summarized below.

Evolution Series E3

The Evolution Series flexographic press, with its totally new platform, instantly appealed to label printers worldwide. “Independent servo drives and flexibility; high quality of printing and speeds up to 500 fpm and numerous inline converting and finishing options—these features of the Evolution Series have been quickly appreciated by their users,” Baldwin explained.

As demand for the Evolution Series continues to grow, Mark Andy claims it delivered and installed more than 50 presses in 2021, around one per week. “Evolution Series prints on many different substrates, with end products including shrink sleeve and inmold labels (IML.) This allows users to cooperate with their customers and brand owners who work in the most demanding industries, like cosmetics, health care and pharmaceutical,” said Baldwin.

Chruslinski added, “Many label converters said they had been waiting for a press that offers flexibility, modularity and compactness. It features servo drive, and its construction offers flexo print units as well as additional options like foil stamping or die cutting.”

Digital Pro

The toner-based Digital Pro 3, an entry-level press, is quite often a first-choice solution for printers starting their journey with digital label printing. “We offer Digital Pro 3 in several versions,” stated Baldwin. “Digital Pro 3 is compact, has a small footprint, and is a flexible and efficient press for short and medium runs. It offers a very fast changeover, increasing press uptime.”

Mark Andy extended its strong partnership with Konica Minolta to transform the digital converting space on June 1, when it announced that it will be the exclusive provider of Konica Minolta’s newest technology, the Accurio Label 400 (AL400), for the labels and packaging industry. Greg Palm, EVP, sales and marketing, saw the move as promising. “Through our strategic partnership with Konica Minolta, Mark Andy is extending its solutions for digital print production to be optimized for mid-to-high volume converters.”

Integrating this new toner-based print technology into its Digital Pro (DPro) line, Mark Andy is developing its first 5-color (CMYK and white) toner end-to-end label and converting solution. Combining Konica Minolta’s strengths in digital marking with its own strengths in web handling, decorating and converting, this new press is expected to “create a single-pass, high-quality, fast and cost-effective solution—hybrid at heart—for the mid-to-high volume label market.”

Mark Andy maintained that “The addition of digital white toner allows customers, for the first time, the flexibility to use clear or metallic substrates for short-run label work without needing to use a flexo plate. Customers will find increased productivity moving between jobs and ease of utilizing white within variable graphics. The new press provides significantly improved print speeds up to 140 fpm. Similarly, converters will realize added savings associated with waste reduction, lower consumable costs and extended duty cycles.

“Incorporating Konica Minolta digital marking technology with Mark Andy’s expertise in converting allows for business expansion and improved customer value for the label converters. This partnership is transforming the industry with the highest quality, most reliable and cost-effective solutions as demonstrated by more than 300 digital press installations. And today, we continue to pursue practical technology solutions for converters of all sizes at a realizable price point.”

William Troxil, president, industrial and production print/North America, Konica Minolta, agreed. “Our organizations share a strong partnership that continues to respond to, and anticipate, the needs of a growing industry. True beneficiaries are label and packaging converters industry wide. Integrating our technologies and overall strengths provides a right-sized solution, allowing for ease of entry into digital transformation.”

Digital Series HD

Baldwin described the company’s flagship hybrid press, the Digital Series HD, this way. “It’s a high-end solution, devoted to highly efficient label and flexible packaging production, both for high volume and small-to-mid runs, including variable data and versioning.”

He later pointed out the potential and high efficiency of Digital Series HD: “Printing and converting or finishing are processed in one pass—this is one of the biggest advantages of hybrid technology. Compared with offline solutions, it makes for significant time and substrate and consumable savings, resulting in a higher production efficiency.”

Digital Series iQ

Last year, Mark Andy launched Digital Series iQ, a new hybrid model co-developed with Domino, manufacturer of the V16610iV inkjet engine, capable of printing with an expanded color gamut (CMYKOV + W). It is powered by a robust Domino N610i UV inkjet module.

“We call Digital Series iQ a True Hybrid as it offers a wealth of possibilities, similarly to our flagship Digital Series HD press. It combines inkjet printing and numerous embellishment and finishing options, including very sophisticated ones. Printing with high quality and speed, up to 230 fpm in rapid mode, Digital Series iQ is a comprehensive solution that opens new markets and opportunities for its users,” said Baldwin.

Chruslinski called the Digital Series iQ a good example of Mark Andy’s hybrid concept: “The inkjet unit, which offers 7-color printing (CMYKOV+W) is a central part of the whole solution. It is accompanied by typical elements of a flexo press, like printing units and finishing and embellishment options. The whole process is realized in one pass, shortening production time and delivery of the final product to the customer.”

David Medlar, VP of digital, Mark Andy, noted, “With the new Digital Series iQ, we can now combine Domino’s established digital UV engine with our world-leading flexo printing material handling and inline finishing.” The press is credited with making inkjet printing, and more specifically digital hybrid printing, attainable for more of the industry’s label and packaging manufacturers interested in expanding into production-level digital printing.

Digital Series iQ, hybrid at heart, can be configured with up to seven UV inkjet colors (CMYKOV+WW). Mark Andy explained that printing components can be integrated to meet each customer’s specific requirements. Print stations, semi-rotary die cutting, rail system and inline slitting are common options selected by some early adopters.

David Ellen, divisional director, Domino Digital Printing Solutions, explained, “We are excited for the partnership with Mark Andy, a company with a reputation for prioritizing their customers’ needs and new technology. By marrying their best-in-class flexographic printing and converting machinery with Domino’s renowned inkjet technology, we expect Digital Series iQ to emerge as a leading hybrid solution for a wide variety of applications.”

sMArt Link

A new software package from Mark Andy, devoted to automated label production, sMArt Link, is a real-time, on-press data collection and monitoring system. It is compatible with new and existing Mark Andy presses as well as other brands, and can be accessed through a cloud-based platform on a single machine, on the production floor or at enterprise level. It helps production managers to make immediate process adjustments, as well as helping executives to make strategic, data-driven decisions.

Gretchen Tobol, product manager, introduced the new software application and reported, “In introducing sMArt Link, we responded to numerous suggestions from our customers. We are very conscious of the need for efficiency and maintaining margins at printing companies these days. These parameters can’t be reached without higher process automation.” It is devoted to label and packaging converters whose operations are hybrid at heart and who want to improve press utilization, efficiency and sustainability.