The future is robotic
One look around any type of packaging or manufacturing trade show and it’s clear how big of a part robotics and automation will play in the future of various industries.
With the gradual evolution of digital solutions over the past few decades, automation in particular has been a talking point for various sectors as it offers solutions but also additional risks.
According to a survey by ABB Robotics of 250 UK SME (small-to-medium enterprises) and large manufacturing companies, 81.2% of companies said they were considering investments in robots due to changes in the industry over the past few years.
According to a survey of 250 UK SME and large manufacturing companies by ABB Robotics in 2021, 81.2% of companies said they were considering investments in robots due to changes in the industry over the past few years”
In an article by The Manufacturer, a trade publication for the manufacturing industry, Nigel Platt from ABB describes how the UK is still behind in adopting robotics to its industries.
The article points out barriers the UK has faced such as the fear of job losses and a reliance on older equipment in legacy businesses.
Platt states that the UK’s tendency to move low cost and high volume manufacturing offshore to countries that are suited to high levels of automation has led to a lack of support and increased challenges for SMEs and small businesses.
Experts in robotics and automation say technology can now be embraced to tackle issues such as employment, sustainability, and skills growth, especially within print and its related industries.
Food manufacturing, packaging, and high-volume/personalised products can all use technology to improve production lines and efficiency in the workplace. So, what are some of the ways this technology can be implemented, and improve business?
The benefits of robotics
“Automation is essential to success,” says Heidelberg, a company that specialises in a variety of print and finishing sectors. Robotics and automation is a core part of its business and the way it operates. The company likens a print shop’s equipment to an orchestra, stating: “With the right instruments, anyone can create a masterpiece.”
Speaking about the success brought on by automation, Heidelberg comments: “This is just as true for specialised industrial operations as it is for small- and medium-sized businesses, which are characterised by their versatility and flexibility. It is not always necessary to implement the full automation package, it is much more important to automate in the right places, according to unique requirements.”
Duplo’s newest machines encompass the latest automation techniques and integrations to modern printers across the country
A specialist in software and mechanics development, Heidelberg offers solutions such as ‘Plate to unit’ which automates printing plate logistics, ‘Prinect’, a software solution to connect print and commercial operations, and the ‘Stahlfolder P-Stacker’ autonomous robot.
The stacker demonstrates the use for robots by implementing an innovative gripper that stacks up to 300 packages per hour.
“When selecting a stacking system, it is important to ensure that it is robust enough to have a long service life and high technical availability, even in an industrial environment,” says Heidelberg.
The company says robust build quality ensures your time is not “overcompensated” by technical failures.
Ian Trengrouse, product manager Post Press Commercial for Heidelberg UK, says: “The greatest changes in productivity come when we remove the human element, be it through automated folding machines, autonomous section changes or the stacking down of sections.
“As soon as the machine becomes the driver, the output increases. This is not always as a pure speed increase, which of course happens with shingling technology, but the overall long time output is increased due to optimised uninterrupted running time.”
Speaking about the trends the company is seeing, Trengrouse adds: “I see a general trend in companies actively investing in our ‘P’ Technology, both folders and stackers. The ‘P’ technology has revolutionised the world of post-press production, alongside our automated folders.
“Finishing has never been so productive. You can print as many sheets as you want, but until they are converted into the final product, flyers, brochures, and books, they are of no use to anyone. So having the most efficient processes in the bindery is key to a successful and profitable business.”
As is evident with companies like Heidelberg, automation has been key to the success of many businesses operating today. The opportunities and evolutions new technologies offer can be seen in one of the company’s end-users, Micropress Printers.
As a user of the ‘P Technology’, Rob Cross, who is director of Micropress Printers, says: “I think you would need more labour on the machine to utilise the full speed enhancement of the P-Folder, but with the automation provided by the P-Stacker we have increased output without needing to add extra labour.
“Since we are now depending more on the machines than on personnel, we need full confidence that a support service will always be available to keep the machines running.”
Cross, who has been a partner with Heidelberg for a number of years, has been fully supported by the company, demonstrating the importance of efficiency, but also how careers in the industry can switch from operating machines to supporting them.
Equally printers have witnessed changes in the industry caused by external factors. Rob Thurston, head of sales at Duplo UK, notes: “In 2021 there was a 13% decline in global print volume for graphics and publications. This led to a raft of redundancies and loss of professionals in the industry as they moved to other jobs outside the industry.
“Now that print volumes are increasing again, the manpower is no longer present. Even before the urgency of the situation was realised, many printers across the UK and Europe saw cost reduction and efficiency as a key component of their business strategy. The fastest way to do this is through automation.”
Speaking about the importance of automation at Duplo, Thurston says: “Automation is the key to everything that Duplo has stood for since its inception. Duplo invented the multi-finisher as we now understand it, a device that slits, cuts, and creases in one package. It’s ideal for common applications such as business and greetings cards, covers, direct mailers, leaflets, concertina folds, in fact anything with the combination of slitting, cross-cutting, scoring and perforating.
Morgana Systems, a division of Plockmatic International, supplies equipment to work in line with digital printing engines from all of the major manufacturers
“Over the years, Duplo has increased its portfolio of finishing equipment to booklet production, automatic saddle stitching, sensory coating, and digital cutting tables, and we’ve steadily developed automation to match market demands.”
A large factor of incorporating robotics and automation is to save time while colleagues can be better used in other areas of the business. Automatic wrappers, packing machines, or cutters, can ensure faster turnaround times and less human error.
“We’ve been able to save almost 20 hours a week spent cutting on the guillotine, time our operators can use to put more jobs through the system,” says Joe Adams, director at Print Junction, and a user of Duplo machinery.
Thurston adds: “The praise we get from our customers regarding the automation of our finishing equipment says it all really. Whether it’s time saved on labour, efficiency saving in pre/post press processes, or the faster turnaround times of multiple jobs. Automation is key to increasing the profit margin of every single one of our hundreds of customers across the UK.”
The praise we get from our customers regarding the automation of our finishing equipment says it all really. Whether it’s time saved on labour, efficiency saving in pre/post press processes, or the faster turnaround times of multiple jobs”
Products such as robot arms are ideal to increase production and take pressures away from staff, who are put off certain production work due to the excessive amount of physical labour.
Another example of robotics coming into use is through IFS, which launched its robot arm system last year to support the Horizon BQ-270V. Its use and intention is typical of the requirements robotics and technology companies are fulfilling today.
IFS managing director Eric Keane, says: “The Robot Arm has been designed to offer a cost-effective operator-free alternative for operations completing simple, on demand, variable, short runs and runs of one.
“It is ideal for production environments running a two or three shift pattern who are struggling with staffing issues. It is also an effective way to ensure social distancing measures are adhered to in busy binderies.”
Needing the right software
In order for businesses to efficiently support robotic and automation solutions, the right software is needed to keep production running with as little errors as possible.
Marc Raad, president of Significans Automation, says: “We believe that the only way for companies to find success in the future is to adopt customised automated workflows that reduce labour and other costs. Our leading-edge services will enable print and packaging companies to achieve unmanned production environments with enhanced communications that will position them to take advantage of the benefits presented by the spread of artificial intelligence and robotics.”
According to industry members, the fastest way to reduce costs and efficiency is through automation
Significans is a software integrator which specialises in delivering automation to the print and packaging industries.
The company has recently worked with Tilia Labs and Infigo (based in West Sussex and Moldova) to create Web Connect+, an initiative to help printers in adopting a web-to-print strategy. The initiative will use online events and demonstrations at industry exhibitions to help businesses with a free global online resource.
Web Connect+ recently held its first webinar, ‘The Benefits of a Complete Connectivity Turnkey Solution’, which took place on June 21st.
Speaking about the project, Sagen de Jonge, co-founder and chief executive officer at Tilia Labs, says: “In our opinion, it’s collaboration that drives innovation in the print industry. Through Web Connect+ we want to be able to reach out to as many of those in the industry that could benefit from automation and AI in web-to-print.
“We’re really excited to get these sessions off the ground, to not only spread the word about the automation possibilities with AI in web-to-print, but to hear the real problems that printers face and how we can help them overcome these challenges.”
Speaking about the importance of educating the industry, Raad adds: “A better job of educating the universities and the schools is what may be needed to better prepare proponents in the future.
“Essentially, it is up to us to teach tomorrow’s generation that there are more efficient ways of doing business. So, let’s teach them to code, to build robotic processes, to automate, and let’s encourage them to be inspired to innovate.”
O Factoid: Research by the ONS between 2017 and 2019 found that 70.2% of the roles at risk of automation are mainly held by women, young people and those who work part-time O
Significans has worked with the likes of EFI, Infigo, and Zünd to offer programming and a range of expertise in custom workflow development, deployment of communication and project management systems, colour management, and end-to-end business integration.
Raad adds: “We offer Robotic Process Automation (RPA) development through to Robotics. This is an innovative approach to automation initiatives for a multitude of companies in the printing and packaging space.
“On-demand printing and packaging requires an e-commerce and web-to-print fulfilment system to automate digital processes. Automation in the form of minimising touchpoints, creating immediate capacity opportunities with background processes overtaking the steps, and creating consistency with fewer errors are common adoptions. For example, input data once and automation has a trigger all the way to print and finishing.”
Food production and packaging is one sector that requires efficient and accurate automation software, especially to avoid errors, and provide vital information like medical descriptions, and allergen information.
Provider of enterprise labelling and artwork management, Loftware is a cloud-based platform that offers an end-to-end labelling solution platform for companies of all different sizes.
The company has also provided software and commentary on the turning point the industry finds itself in and considers itself in a unique position in the way it is able to offer solutions others have not considered.
New products have meant technology is able to personalise labels, along with transporting heavy objects
Troy Walker, global artwork and packaging solutions executive at Loftware, comments: “The artwork surrounding a product is just as valuable and important as the product itself and, as such, it requires a well-managed process. Artwork Management is therefore of the utmost importance. Not only does it cover the graphical design of a label but also the content of barcodes and product details (including ingredient and allergen lists and other regulatory requirements).”
Walker adds: “Automated Artwork Management solutions are the answer to a problem that often goes unknown and undiagnosed within design, marketing, regulatory, compliance, legal, and packaging departments. An automated Artwork Management solution, accessible by all relevant stakeholders and able to manage both workflows and updates related to the packaging artwork, ensures everyone always has access to important resources.
“The added speed, consistency and ease of collaboration can create a sense of calm confidence in a department prone to becoming either chaotic or disconnected. Heavily regulated industries – ones with packaging elements that must meet regulatory compliance – most acutely feel the pressure for artwork to be accurate and efficiently managed. These organisations can’t afford to pass up the benefits of automating their processes.”
Walker brings up the many disadvantages not using automated software can cause. Just as technology can be used to enhance security and reliability, automated processes can also help to bridge gaps and overcome problems previously thought to be un-solvable.
“There have been instances where companies using this type of manual process have seen their files lost, damaged, or even destroyed in fires,” says Walker. “Other companies use PDFs, FTP sites (for uploading/sharing files), and solutions like SharePoint to manage artwork. In these environments, the companies have four or five different tools, none of which integrate or ‘talk’ to one another, increasing the likelihood of errors, delays, and compliance issues.”
Opportunities of automation
Over the past three years the increase in e-commerce has had a large impact on the need for automated systems. Companies have worked to ensure online products are organised and fed through the system in a way to avoid errors and improve efficiency.
Walker says: “The continued surge in online shopping has brought a renewed focus on labelling and packaging to accommodate increased packing and shipping as the public moves away from traditional retail and purchasing from brick-and-mortar establishments. E-commerce storefronts are now all the rage, and those providers understand that labelling is a key function that has a significant impact on business.
“The e-commerce boom presents both opportunities and challenges for companies that need labels for product identification, warehousing, order management, shipping, inventory, and other activities. Customer-facing labelling has become equally as important with the next competitor just one mouse click away.”
Businesses moving to hybrid working and more digital workspaces have also meant technology companies are encouraging the adoption of new solutions to tackle the problems faced by companies working via out-dated systems.
EKM Global, a supplier of managed print service software, has over 20 years’ experience of helping different companies optimise print resources and operations.
Colin Bosher, chief executive officer at EKM Global, says: “Quite simply, the need for automation and robotics in the form of M2M technologies like ours is typically driven by the need for lower operational cost as the industry continues to be commoditised.
“Consequently, the industry can no longer easily afford to throw people at a manual process. The value has therefore shifted from being device-centric to being far more concerned about ensuring highly efficient remote service management on a repeatable and scalable basis regardless of brand. Post pandemic, hybrid office and modern workplace have accelerated the need for next generation infrastructure to enable global OEMs (original equipment manufacturers) and volume channel resellers to offer a better solution at lower cost without the operational overhead.”
The worlds of automation and robotics have unsurprisingly seen a large amount of innovation over the past few years.
Bosher explains: “Having established EKM at least ten years ahead of similar remote monitoring ISVs, we have continuously and relentlessly optimised our core system algorithms to ensure that we provide the most accurate and reliable industry approach to dramatically reduce opex (operational expenditure).
Heidelberg states the key to success is in the coordinated interaction of people, processes, materials, and machines
“More recently, we have been developing complementary technology modules that integrate physical and electronic data feeds, including leveraging augmented reality and some of the latest biometric and security innovations.”
While the UK may be behind in regards to fully adopting future innovations, investments in software, automation, and the likes of AMRs (autonomous mobile robots) have put us on the right track.
Many companies are already offering game-changing solutions that can alleviate staff from the manufacturing floor, providing the likes of robots for personalised products, automated systems for photo printing, or intelligent cutting and finishing services.
Raad concludes: “Print companies certainly have a choice: to invest and advance by way of modernising to avoid being left behind, or they can sell out. Conceivably, printers and converters will eventually have less value to present to the brands without robotic systems that include RPA and finite analytics.”
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