Laser Diecutting - Label and Narrow Web

Apr 03, 2025

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This versatile and flexible digital finishing option has seen increased adoption in recent years.

November 15, 2023

By: Greg Hrinya

The concept of digital is not limited to simply printing assets. There is a groundswell forming for digital finishing, as well, as label converters look to capitalize on the same flexibility and versatility present with their digital presses. Make-ready time is drastically reduced, as there are no dies or tooling for which to account.“Laser diecutting is the process of using a focused laser beam to effectively cut through materials and allow for on-demand production of various shapes and sizes,” explains Shaan Patel, business development manager, Arrow Systems. “The main benefits are that the process allows manufacturers to produce short run labels with very little in the way of prepress. All that is typically needed is a design file, and the laser finisher does the rest. This allows for seamless production of short and medium run jobs.”The process features no tools or consumables, has a long lifespan, and there is an automatic workflow for quick job changeovers and no responsibility for the operator. “The make-ready only takes a few minutes,” notes Floriana Montella, DigiLase and DigiJet product manager, A B Graphic International. “It’s a very simple process that only requires a quick material calibration and the material is ready to be laser cut. It’s also safe, with a Class 1 laser product, and it’s versatile, as most of the substrates can be laser-cut.”Laser diecutting is not a new phenomenon, either. For example, Delta ModTech has been integrating lasers into its converting systems for over 15 years. The company has found success tailoring solutions to its customers’ unique converting needs. Printers can upload a drawing to the HMI and start cutting right away, and product recipes and programs are easily saved and recalled.“In recent years, the market has been showing interest in a solution that satisfies the digital concept; this has led to significant growth,” says Virgilio Micale, director of sales, Cartes. “Laser technology is undoubtedly the one that most complements this concept, especially in those countries where flexible dies are not available in a short period of time. Cartes has always believed in this technology, so we’ve invested a large part of our energy and resources into automating the processing, looking for faster make-ready starts and waste savings.”Cartes has optimized its laser technology for ease of use, where converters can learn the process in a relatively short period of time. All machine management systems have a user-friendly approach, especially for those users with no experience, notes Micale.TLF Graphics, a printing company based in Rochester, NY, USA, recently installed the Labelmaster from SEI Laser. TLF Graphics generates 33,203 transactions per year, and the versatility provided by laser diecutting will help promote faster turnarounds for customers. For example, a recent quote request came in for 25 different labels in small quantities. Finishing that job without the Labelmaster would require $4,000 in dies. TLF Graphics can now promise no films, no plates and no dies with a complete digital process, from order entry through to shipping.“We have a substantial fleet of digital presses that can print very fast,” explains Bob McJury, president, TLF Graphics. “The bottleneck in finishing required a lot of overtime. Margins in the printing business are thin, and we can’t afford to lose a shift due to downtime for equipment repairs. We had to come up to speed with our finishing equipment. The Labelmaster is an important tool to deliver speed and service. Eliminating overtime for finishing will be a big savings with improved productivity and cost reduction.”Laser diecutting is no longer a novel concept. Like TLF Graphics, many converters are seeing the value present with these technological advancements. Patel says, “Adoption has been growing for the past few years and seems poised to continue in that trajectory. Whereas 8-10 years ago, there were only a few manufacturers of the laser technology, this year in Brussels we saw at least a dozen new manufacturers entering the market with various levels of finisher. We plan to continue to stay ahead of the rest by integrating the laser finishing technology in with our digital water-based inkjet solutions.”“With the birth and quick expansion of e-commerce, the laser has become the only solution to fulfill short runs and immediate deliveries,” adds Montella. “This trend was dramatically magnified during the pandemic when the tooling was untraceable or required very long lead times. During those two years, laser technology saw a rise in the double of machines sold compared to normal times. Since then, e-commerce has stabilized its position in the market, but it’s still growing, allowing both B2B and B2C to expand globally.” In the future, affordability will help drive adoption. “The main growth will be in the reduction in price as more and more companies get into this segment,” comments Patel. “This will help to drive the technology into the market, as more players come in, thus creating a more competitive market but also ushering in new ways to work with the lasers. We feel this market is just getting started, and as new developments come out, such as higher power lasers, dual and quad lasers, etc., we will continue to see growth from the traditionally analog manufacturers of labels.”

The label printing industry is as dynamic as it’s ever been. Consolidation, innovation and the proliferation of digital technologies have emerged as the prominent topics dominating the headlines.

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