Mirmar shifts half of its label jobs to hybrid with second Mark Andy DSHD

A targeted strategy for short and medium run efficiency

The European label converting sector in 2026 continues to face a complex matrix of operational challenges, driven primarily by the relentless proliferation of SKUs and the corresponding decline in average run lengths. Responding directly to these market signals, Spanish label converter Mirmar S.A. has solidified its digital production strategy by installing a second Mark Andy Digital Series HD (DSHD) hybrid press at its Valencia headquarters.

Mirmar, a family-owned business with a workforce of 50 employees, converts over 24 million square meters of substrate annually operating on double-day shifts. Historically relying on conventional flexography, the company operates six Mark Andy Performance Series flexo lines. However, as the market demanded more agility, the converter introduced its first 430-millimeter (17-inch) DSHD hybrid in 2023. The operational success of that initial investment created a clear roadmap for this second installation, effectively doubling the company's hybrid capacity and optimizing its entire pressroom workflow.

According to Jaime Mir Pastor, CEO of Mirmar, the integration of a second hybrid press allows the company to systematically divide its workload based on run lengths. The two DSHD machines now process approximately 50% of the total jobs received by the converter. Interestingly, these jobs account for less than 20% of the company's total production volume. By absorbing this high frequency of short and medium runs, the hybrid presses free up massive capacity on the conventional Performance Series equipment, which can now run uninterrupted on long-run, high-volume orders.

Technical architecture of the DSHD installation

The newly installed hybrid press mirrors the exact specifications of Mirmar's first unit, ensuring seamless operator transition and matching print quality across the production floor. The core of the machine is a high-resolution, seven-color UV inkjet engine featuring CMYK plus orange, violet, and white. This configuration is capable of printing at 1200 dpi at production speeds reaching 73 meters per minute (240 feet per minute).

To maintain the efficiency of a single-pass workflow without the need for offline finishing, the press is equipped with two flexo stations on either side of the digital module. These stations handle spot colors, cold foil applications, and varnishes. Furthermore, the machine features web turn bars for delamination and relamination processes, along with a specialized web translator—often referred to as a Gizmo—designed specifically for manufacturing peel-and-reseal labels.

The financial and operational metrics behind the investment are striking. On standard flexo equipment, Mirmar typically processes three or four jobs per shift, requiring up to 60 minutes for makeready. The DSHD platforms have slashed that setup time to 20 minutes or less, allowing the digital-flexo hybrids to complete around 10 jobs per shift. Combined, the two hybrid presses are now delivering approximately 5 million linear meters of labels each year.

Capturing value in cosmetics and home care

The ability to combine digital print quality with inline converting has allowed Mirmar to strengthen its position in premium markets. The cosmetics and home care sectors, in particular, have become significant growth drivers. These industries demand complex label structures, frequent regulatory text updates, and highly opaque whites that rival traditional screen printing.

The single-pass hybrid system is ideally suited for these requirements. The lack of a "click charge" on the Mark Andy DSHD platform also provides Mirmar with highly predictable costing structures, making short-run premium labels more financially viable. Furthermore, the peel-and-reseal capabilities add immense value to food and personal care packaging, where extended content labels are increasingly mandated by regulatory bodies.

Looking forward, the Spanish converter is already mapping out its next phase of technological adoption. To combat the broader labor shortages affecting the printing industry globally, Mirmar is exploring further automation tools and evaluating investments in linerless label production. The swift commissioning of this second machine—which was executing commercial jobs within a week of its arrival—highlights the strength of the ongoing partnership with Mark Andy, providing Mirmar with a highly flexible foundation for the remainder of the decade.

The strategic division of labor between conventional flexo and single-pass hybrid technology represents the most pragmatic approach to modern label converting. Will pure digital printing with offline finishing eventually give way entirely to these all-in-one hybrid ecosystems for medium-volume producers? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai