US label converters increase investment in new technology

Gallus is reporting strong momentum in the US label printing market, with more than ten new press investments secured since the beginning of its 2026 fiscal year. The investments highlight growing demand for flexible production systems capable of handling changing product requirements, shorter runs and increasingly complex label applications.

The developments come as the North American label market is projected to maintain steady growth, with annual expansion of around 2% expected through 2028. According to Gallus and Heidelberg, US converters are responding to this outlook by investing across a range of flexographic, digital and hybrid printing platforms.

Hybrid technology combines multiple processes

One of the latest investments comes from Hub Labels in Maryland, which has added a new Gallus Five to its existing portfolio of Gallus presses. The system combines flexographic and digital inkjet printing on a single platform, alongside integrated embellishment and die-cutting capabilities.

The hybrid configuration allows converters to combine different printing technologies within the same production environment. This can provide greater flexibility when handling jobs with different volumes, specifications and levels of customisation, while reducing the need to move work between separate machines.

Shorter runs drive demand for flexibility

Increasing product variety is creating greater pressure on label converters to manage high numbers of stock-keeping units while maintaining efficient production. Shorter print runs can make conventional production setups less efficient because frequent job changes increase downtime and reduce machine utilisation.

Hybrid systems are designed to address this challenge by allowing different production technologies to be used within the same workflow. Digital printing can provide flexibility for shorter and more variable jobs, while flexographic printing remains suited to applications requiring efficient production at larger volumes.

Modular systems adapt to changing requirements

Gallus is also promoting its System to Compose concept, which allows converters to configure printing systems according to their specific production requirements. Units can be added, adjusted or removed as business needs evolve, giving manufacturers greater flexibility than fixed machine configurations.

The approach is designed to allow production equipment to evolve alongside a converter's business. Instead of replacing an entire press when requirements change, manufacturers can potentially adapt individual components or add new capabilities to an existing configuration.

Lower ink consumption and energy use

The Gallus Five investment at Hub Labels also highlights the industry's focus on production efficiency. Combined with Heidelberg's Saphira UV05 ink set, the press can operate at speeds of up to 100 metres per minute while using less ink due to the high pigmentation of the inks.

The inks are also designed for LED curing, which can reduce energy consumption compared with conventional drying technologies. Lower ink consumption and energy requirements can contribute to reduced operating costs while supporting manufacturers' efforts to improve the environmental performance of their production processes.

Greater productivity for high-SKU production

The new press also provides a 17-inch printing width, allowing Hub Labels to handle a broader range of jobs. The company expects to use the system particularly for shorter runs, moving these jobs away from existing presses and improving overall utilisation across its production floor.

Reducing changeover times is especially important for converters managing high numbers of SKUs. Faster transitions between jobs can increase productive machine time while allowing manufacturers to respond more efficiently to customer requirements.

Modularity becomes increasingly important

The growing interest in modular and hybrid printing systems reflects broader changes in the label and packaging industry. Brand owners increasingly require more versions, customised designs and shorter production runs, while converters need to maintain competitive costs and consistent quality.

Flexible production platforms can help manufacturers respond to these pressures without sacrificing the efficiency of established printing processes. The combination of digital and conventional technologies also allows converters to select the most appropriate production method for each application.

Label production moves towards adaptable manufacturing

Gallus' latest US investments demonstrate how label printing is evolving towards more adaptable production environments. Rather than relying on a single printing technology or fixed machine configuration, converters are increasingly looking for systems that can accommodate changing volumes, formats and customer requirements.

As the North American label market continues to expand, investments in modular presses, hybrid printing and more efficient curing technologies could become increasingly important. The trend highlights a wider shift towards production platforms that combine flexibility, automation and efficiency while giving packaging converters greater control over increasingly complex manufacturing demands.