In an industry grappling with a critical shortage of skilled labor and escalating demands for efficiency, four leading players are joining forces to redefine the future of flexographic printing. Asahi Photoproducts, Allstein, Esko, and Kongsberg PCS have announced a groundbreaking collaboration, set to debut next-level flexo automation at an exclusive open house event in Herford, Germany, on October 7, 2025. This joint showcase not only addresses pressing workforce challenges but also positions flexography as a formidable competitor to rotogravure, particularly in markets where gravure has long dominated.​

A Response to Industry Pressures: Automation as a Strategic Imperative​

The global printing industry has been sounding alarms about the dwindling pool of skilled workers for years. From press operators to finishing specialists, the gap between labor supply and demand has widened, slowing production cycles and raising costs. Flexographic printing, valued for its versatility in packaging, labels, and folding cartons, has not been immune—manual setups, complex color matching, and post-press adjustments have traditionally relied on seasoned experts, making the sector vulnerable to workforce shortages.​

Against this backdrop, the collaboration between Asahi, Allstein, Esko, and Kongsberg represents a pivotal shift. By integrating their respective technologies, the partners aim to automate end-to-end flexo workflows, minimizing human intervention in repetitive tasks while amplifying the impact of skilled labor on high-value decision-making. “Automation here isn’t just about speed—it’s about sustainability,” notes a spokesperson for Asahi Photoproducts. “By reducing manual touchpoints, we’re cutting errors, waste, and energy use, all while making flexo more accessible to a new generation of operators.”​

Synergizing Expertise: What Each Partner Brings to the Table​

The strength of the collaboration lies in the complementary strengths of the four companies, each a leader in its niche:​

• Asahi Photoproducts: A pioneer in flexo plate technology, Asahi contributes its advanced AWP™ (Asahi Water-Washable) plates and automation-ready imaging systems. These plates, compatible with high-speed digital workflows, reduce setup time by enabling pre-press standardization—critical for seamless integration with automated press systems.​
• Allstein: Renowned for its flexo presses, Allstein showcases its latest servo-driven, inline printing lines. Equipped with AI-powered color management and auto-register systems, these presses adapt to material variations in real time, ensuring consistent quality across runs without manual adjustments.​
• Esko: A leader in packaging workflow software, Esko provides the digital backbone: its Automation Engine connects pre-press design, plate imaging, and press operations into a unified digital thread. This allows for automated job scheduling, version control, and data-driven adjustments, eliminating bottlenecks between design and production.​
• Kongsberg PCS: Specializing in post-press finishing, Kongsberg brings robotic cutting, creasing, and die-cutting solutions. Its automated material handling systems sync with printing lines, enabling “lights-out” post-processing—where finished sheets are converted, stacked, and sorted with minimal human oversight.​

The Open House Showcase: A Glimpse into the Future of Flexo​

At the Herford open house, attendees will witness a live, end-to-end automated flexo production line that embodies this collaboration. Key demonstrations include:​

• Rapid Job Changeovers: A single operator initiates a switch between a beverage label and a cosmetic carton job via Esko’s interface. The system automatically adjusts Asahi plates, Allstein press settings, and Kongsberg finishing tools—completing the changeover in under 10 minutes, a fraction of the 45+ minutes required manually.​
• AI-Driven Quality Control: Cameras integrated into Allstein’s press feed real-time data to Esko’s software, which flags color deviations or registration errors. The press then self-corrects, while Kongsberg’s finishing system diverts defective pieces—all without operator input.​
• Sustainability Metrics: A live dashboard displays resource savings: 30% less ink waste (via precise plate imaging), 25% lower energy use (from optimized press speeds), and 15% fewer material scraps (thanks to Kongsberg’s precision cutting).​
• Skill Augmentation: Rather than replacing workers, the system empowers them: operators monitor workflows via tablets, address exceptions, and optimize recipes—shifting their role from “doers” to “supervisors” of automated systems.​

Market Impact: Flexo as a Viable Alternative to Gravure​

Beyond addressing labor shortages, the collaboration aims to position flexo as a credible rival to rotogravure, particularly in Asia—a region where gravure dominates high-volume packaging due to its historical efficiency in long runs.​

Flexo, long seen as ideal for short to medium runs, now competes in longer runs thanks to automation: the showcased line matches gravure’s speed (up to 500 meters per minute) while offering greater flexibility for SKU proliferation. Additionally, flexo’s use of water-based inks aligns with global sustainability regulations, a growing priority for brands in food, beverage, and personal care.​

“Gravure has held sway in Asia for its consistency, but automation is erasing that edge,” explains an industry analyst. “Flexo’s lower setup costs, faster changeovers, and eco-friendly profile—paired with this level of automation—make it a compelling choice for brands navigating both labor constraints and sustainability goals.”​

Registering for the Event​

Interested attendees, including printers, converters, and brand owners, can register via the partners’ official channels. The open house will include hands-on workshops, technical deep dives with engineers from all four companies, and networking opportunities focused on scaling automation in flexo operations.​

As the printing industry grapples with unprecedented challenges, collaborations like this underscore a clear message: automation is not just a solution—it’s a catalyst for reinvigorating flexographic printing, making it more efficient, sustainable, and resilient in the face of change.

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