Discover your next big idea at PACK EXPO Las Vegas this September
Experience a breakthrough in packaging & processing and transform your business with solutions from 2,300 suppliers spanning all industries.
REGISTER NOW & SAVE

Digital printing with a whole new level of in-line integration

By yoking together the priming, printing, and finishing stations of its digital printing operation in one integrated line, ILS gains significant manufacturing efficiencies.

At the heart of the integrated prime/print/finish line is the HP Indigo WS6000 digital press.
At the heart of the integrated prime/print/finish line is the HP Indigo WS6000 digital press.

Long regarded as one of the leaders in the ongoing and rapidly accelerating growth of digital printing in the label and packaging space, Innovative Labeling Solutions has taken digital printing another step forward by assembling what it calls the world’s first complete in-line digital print production line. Because it efficiently integrates in one line operations that have traditionally been carried out separately and sequentially, this move will reduce production steps, minimize work in process, and improve overall operating and economic efficiencies.


At the heart of the new line is one of the three HP Indigo WS6000 digital presses from HP in operation at the Hamilton, OH, facility of ILS, which produces not just labels but also a broad array of folding cartons, shrink sleeves, and flexible packaging, too. The other two components joining the press in the single integrated line are an upstream HP corona priming unit and a downstream finishing system from Delta Industrial Services. To best understand and appreciate the operating efficiencies this in-line integration brings, it helps to take a look at how priming and finishing are done conventionally. We’ll start with finishing only because ILS put its Delta Spectrum II finishing system in line with the WS6000 before yoking the in-line priming unit into the line.


“Finishing” in this context means a number of things. In some cases it refers to finishing steps such as die-cutting that are involved with conventional printing. But this is digital printing, so it also means things that are inherently necessary when printing with HP Electroinks. For example, a post-print lay-down of varnish or an overlamination of a clear protective substrate is always necessary to protect the inks. Because it can now be done right in line, it saves a lot of time on the set up that would be required if the substrate had to be taken to an off-line varnishing or laminating station. Sean Gallagher, director of innovation at ILS, provides other examples of the advantages of inline finishing.


“If we need to flexographically apply a spot color, we can do that on the Delta Spectrum II, so we can avoid the set up time and queue time it used to require when it was done off line. We’re also seeing better, tighter registration by applying that spot color in line. Or look at the shrink sleeve labels we produce. In one smooth pass we are now able to digitally print, apply our COF [Coefficient of Friction] varnish, and slit all in line. It’s all so much more efficient.”


In-line finishing also helps on jobs where metallic inks are involved, says Gallagher. “The Indigo digital press can’t print metallic inks because of the electromagnetic charge of the ElectroInks. So we normally have to lay down those metallic inks flexographically on a second station. Now with this in-line configuration, we don’t have to mount the substrate on an off-line press. We print the metallic inks flexographically on the Delta Spectrum II.”

Coding, Marking, and Labeling Innovations Report
Explore our editor-curated report featuring cutting-edge coding, labeling, and RFID innovations from PACK EXPO 2024. Discover high-speed digital printing, sustainable label materials, automated labeling systems, and advanced traceability solutions that are transforming packaging operations across industries.
Access Report
Coding, Marking, and Labeling Innovations Report
Researched List: Engineering Services Firms
Looking for engineering services? Our curated list features 100+ companies specializing in civil, process, structural, and electrical engineering. Many also offer construction, design, and architecture services. Download to access company names, markets served, key services, contact information, and more!
Download Now
Researched List: Engineering Services Firms