Case Study | LabelLine
How Labelnet Improved Flexo Label Press Efficiency by 30% and Cut Lead Times
The business needed a step-change in throughput, lead time and margin – without adding headcount or operational complexity.
Since installation, makeready times have improved by approximately 30% without increasing operator dependency, setup waste has reduced by around 25%, and comparable job sets are completed 40% faster.
At the same time, turnover has grown by 120%, while lead times have shortened from 2–3 weeks to 10–12 working days, despite doubling turnover. This is a case study in measurable flexo label press efficiency.
The Production Environment
Labelnet operates in a competitive, fast-moving label market where quality, repeatability and responsiveness define performance. Prior to installing the FL3, the company ran older-generation presses that limited throughput and constrained growth.
The business required a platform that could:
- Increase production efficiency
- Improve print consistency
- Support wider web capability
- Enable future growth
Flexographic label printing was already central to their production strategy. The question was how to make it faster, leaner and more commercially scalable.
The Challenge: Makeready, Waste and Lead Time Pressure
Before the FL3 installation, Labelnet operated with standard lead times of 2–3 weeks. Makeready processes were longer and less predictable, and material waste during setup had a measurable impact on margins.
As volumes increased and customer expectations tightened, three pressures emerged:
- Reduce makeready time in label printing
- Cut setup waste and improve margin
- Increase label production throughput without expanding headcount
Growth without efficiency would have created operational strain. The solution had to improve performance without adding complexity.
The Solution: A High-Efficiency Flexo Label Press
The FL3 provided a step change in production control and stability.
“The FL3 gave us stability and speed without adding complexity. We reduced makeready, improved lead times and grew the business — all on the same platform.”
— Rob Lorkins, Managing Director, Labelnet
Measured improvements include:
- 30% reduction in makeready times
- 25% reduction in setup waste
- 40% faster completion of comparable job sets
- Lead times reduced to 10–12 working days
- Wider web width delivering approximately 10% margin improvement on qualifying jobs
Despite moving from two presses to one and increasing turnover by 120% since 2014, Labelnet has maintained faster, more predictable production.
The press also supports sustained high-speed output, with long-run jobs such as 280,000 metres printed at 130 m/min demonstrating consistent performance. In addition, production structure has streamlined. A single prepress operator now supports two presses, improving workflow efficiency across shifts.
The transition was completed without disruption to customer delivery schedules, with operators fully up to speed within a short timeframe.
Operational Impact: Stability and Repeatability
Beyond speed gains, the most significant improvement has been production stability.
Repeatability has improved first-off accuracy and reduced rework. Automation and web control have contributed to more consistent registration and less variability between runs.
This has translated into:
- More predictable scheduling
- Reduced manual intervention
- Greater operator confidence
- Improved utilisation of factory floor capacity
Flexo press reliability has been central to this. More than a decade after installation, the FL3 remains a production workhorse within the Labelnet facility.
Commercial Impact: Growth Without Complexity
The operational improvements have enabled measurable commercial growth. Since 2014:
- Turnover has increased by 120%
- Lead times have shortened
- Capability has expanded into new markets
- Quality improvements have supported broader customer acquisition
The decision to invest was driven by three factors: market growth, quality enhancement and efficiency gains. Existing jobs improved in quality and margin, while new capability allowed Labelnet to pursue wider customer opportunities.
This wasn’t incremental optimisation. It was structural change. It became a platform for scalable growth.
Labelnet’s experience demonstrates that modern flexographic technology is not defined by speed alone. It is defined by:
- Reduced makeready time
- Lower material waste
- Increased throughput
- Predictable lead times
In a competitive label market, production stability and measurable efficiency improvements create structural advantage.
For Labelnet, flexo became not just a printing process, but a growth engine.
Frequently Asked Questions
Modern flexo presses can reduce makeready times by 20–40%, depending on automation and workflow maturity. In Labelnet’s case, a 30% reduction was achieved without increasing operator dependency.
Yes. Improved web control, registration and automation can reduce setup waste by 20–30%, improving overall margin. Read our blog on how flexo can help reduce waste here.
Flexo remains one of the most efficient processes for medium to long-run label production, offering high speeds and repeatable quality.
With proper maintenance and engineering quality, flexo presses can deliver reliable production performance for more than a decade. Read our blog on why investing in a flexo press makes sense here.
Looking to achieve similar results in your operation?
30% less makeready. 120% more growth.
Find out how the right press investment can transform your production. Talk to Our Team.