Launching into labels

The combination of labels and the use of wide-format print might seem to be something of an oxymoron but, with the current quest by companies to apply their existing technologies to different areas, this is proving to be a sensible addition to many service portfolios. Users experienced in the poster and display markets find it straightforward to generate these smaller products, and machines, materials and associated software are all able easily to handle smaller, repeat applications.
As seen with the growth in popularity of print-and-cut machines, labelling is a sector that is increasingly attractive to the wide-format print community. Machine manufacturers are addressing this arena with specialist solutions that work on a narrower web principle, such as the new Epson Surepress and the Durst Tau, but users of wider printers can also take advantage of inkjet technology to pursue these applications.
Back in the early days of computerised sign-making, label production became an automated reality with cutting plotters that could be used for multiple jobs strafed across and down a single sheet of material. Early full-colour printing systems using thermal transfer technology also offered complementary cutting capabilities, and this led to digital durable results which became popular for stickers and decals as well as signs and displays.
Today's machines are very different beasts to those of yesteryear. Most of the roll-fed unit which are suited to the output of labels use solvent-based ink formulations and, thus, provide a degree of durability of output which, of course, can be overlaminated for extra length of life. The improvements generally in printheads and drop quality as time has passed has also helped combination print-and-cut machines retain their place in the label and decal production sector. These same benefits can, of course be found in separate units where independent options are used for the two parts of the overall process.
Nonetheless, in the wide-format sector where users are wanting to output labels, there is a tendency to opt for the perceived benefits of a combined print-and-cut solution which not only removes the hassle of running two machines but also is optimised to slot tidily into the user's workflow.
Wide-format print producers looking to extend their skills and capabilities into new market areas are adopting label output as a value added service. The benefits are clear, with original files tending to be small and not processor intensive; longer runs can be left to their own devices and don't need to be watched over constantly. Similarly, for the self-adhesive market there are plenty of lighter weight cast and calendered films which are suitable for these applications.
As one of the early protagonists of label and decal printing using sign-making machines, Roland DG no longer has its place alone in the print-and-cut sector having been joined by Mimaki with its own solvent-based family of options. Having acknowledged that this type of printing was always likely to become a target market for its combination systems, Roland has continued to feature these machines strongly in its latest portfolios of options. Not surprisingly, and very sensibly, its new metallic ink has been incorporated into the company's Soljet Pro III XC-540MT and the more recent VersaCAMM VS-640. Both of these print-and-cut options demonstrate clearly how this manufacturer perceives its technology to be shifting away from producing just displays and contour-cut signs to speciality labels and decals.
Mimaki's CJV30 series of print-and-cut machines has also become popular with label producers, with the family of four solvent-based units resulting in a good choice of widths according to end-user needs. Like Roland, this company recognises the importance for material stability when printing, and then cutting longer run jobs, relies on continuous registration mark detection; this is particularly vital on label applications where cut accuracy only needs to be fractionally out of line to render the entire job ruined.
Although Mimaki doesn't have a metallic option in its CJV30 machines, there is a good, opaque white which can be added to six-colour applications whilst, for faster throughput, these machines can be used in a twice x four-colour mode. Certainly creativity can be incorporated into labels using the maximum numbers of inks at the highest resolution but many can be produced more than adequately in four colours, particularly where solid shades are a representative element of the job or when speed is of the essence.
Solvent-based roll-fed machines aren't the only type of combination units now available for more eclectic applications. When Roland DG first launched its UV-curable VersaUV print-and-cut unit some were surprised to learn that this is, essentially, a roll-fed machine with a width of only 762mm. Although it was immediately obvious that its quality was stunning it took the label printing faction a while to acknowledge that here was a system which could be used with related stocks as well as more unusual materials.
Now revised to the LEC-330, which offers higher resolution and improved throughput speeds, the Roland VersaUV printer also has white and clear varnish; combined with the flexibility of the ink formulation used in this unit and its LED curing has made this another option for digitally produced labels. This is helped by the fact that it can be used on a wide range of different metallic and synthetic papers and foils as well as more conventional label stocks. Again, and perhaps not immediately obvious, the fact that layers of clear varnish can be put down to produce tactile finishes means this feature can be used for practical as well as aesthetic uses.
One of the obvious advantages of label printing which is found only in digital production is the ability to produce runs which vary in content. The demand for this not only is evidenced with commonplace examples, such as sequential numbering, but also in personalised and versioned applications increasingly being found in the gift and promotional marketplaces. A unique, customised label on a bottle of wine or a box of chocolates tends to hold a far higher intrinsic value than a run of the mill product and, again, print service providers can easily add this functionality to their existing capabilities.
It is not surprising that there is additional appeal within the print-and-cut machine sector for label printing and this extends into prototyping, proofing and related areas in industrial applications. These applications are not restricted to roll-fed production units and a growing number of UV-curable flatbed and hybrid machines are also used for the production of such jobs. Now that quality and adhesion, plus curing principles, have improved markedly to make this ink formulation suitable for a wider range of jobs, decals and stickers have joined the output opportunities being taken on-board by display producers and sign manufacturers.
Those who have already invested in higher-end contour cutting systems can put together a true print-to-cut workflow which, by definition, is ideal for label production. But none of this would be easy without the software to drive these applications. This not only handles automatic arrangement and alignment of images in a nested format but also ensures that the cutting path is delineated clearly, with registration marks being included so that the cutter knows the correct positioning point on the printed material.
Not every label comes with a self-adhesive backing, and many of those used in outdoor durable locations can now benefit from being produced on durable substrates. Differentiation of the term label from that of sign is normally worked out according to size, and the world has generally come to accept that the former, along with decals and stickers, are designed to be small, informative objects which provide identification plus decorative or industrial detail.
Using wide-format machines and related cutting equipment, whether integral or not, has freed up the restrictions imposed by the cost implications that were always evident when creating dies or formes for label production. Shorter run jobs are now easy to shape as part of the digital workflow, and variations within a single data file aren't a problem. Labels don't need merely to be square or rectangular, and nor do they have to follow any convention in terms of outline. The accuracy of today's cutters, in conjunction with the quality of the print itself, means that designers are at liberty to create complex shapes and styles knowing that computerised cutting techniques can now easily accommodate even the tightest angles and most intricate curves.
Personalisation is finally making its mark in the wide-format arena and, although some Rip suppliers have incorporated this feature into their software, there is now growing interest amongst display printers who want to simplify customisation. This can only really be achieved sensibly and cost-effectively by using automation, a feature which has been available in narrower format digital production for many years. For the label sector, this feature has opened new doors to personalised production by removing the manual element of adding individual data elements to a job.
Overall, the ethos surrounding wide-format print and the ease with which nested jobs can be created and output means that labels are a simple, logical add-on for existing machine users. Combined with the growth of this market sector for low volumes and customisation, even the lowest cost combinations of printer and cutter can be used to produce high quality products.