BOBST consolidates Supertape label production from six presses to two and boosts uptime to 70 percent

A radical reduction in hardware footprint yields major operational gains

The label and narrow-web sector is increasingly moving away from sprawling, multi-machine factory floors in favor of highly automated, hybrid platforms. BOBST has provided a clear operational benchmark for this trend with its latest installation at Supertape. The adhesive specialist has completely overhauled its production architecture, replacing a legacy fleet of five traditional flexographic presses and one digital toner machine with just two modern BOBST platforms: a DIGITAL MASTER 340 and a MASTER M6. The consolidation has driven average production uptime from 50 percent to 70 percent.

This equipment reduction addresses a critical bottleneck for converters operating in high-demand segments. Supertape, which has maintained a supplier relationship with BOBST for over 35 years, recognized that its previous six-machine setup was becoming a liability in terms of floor space utilization, energy consumption, and workflow complexity. By transitioning to a dual-press configuration, the company has not only reclaimed factory space but also accelerated its output, now running label production at consistent speeds of 90 to 100 meters per minute.

Hybrid architecture and in-house finishing

The technical core of this transition relies on bridging the gap between digital flexibility and flexographic volume. The DIGITAL MASTER 340 operates as a modular all-in-line label press, delivering a 1200 DPI resolution with digital white capabilities. This hybrid approach allows the converter to shift jobs that were previously bound to traditional flexo onto a more agile platform.

Leander Dekke, Production Manager at Supertape, confirmed the immediate impact on operating expenses. The shift to the DIGITAL MASTER 340 has drastically reduced changeover times and eliminated significant plate costs for specific label runs. Meanwhile, the MASTER M6, a fully digitalized flexo press equipped with DigiFlexo automation, has taken over the heavy lifting for tape production.

Beyond raw printing speed, the integration of inline finishing capabilities has altered Supertape's supply chain dynamics. Dekke noted that the new setup allows the company to handle all enhancing and finishing processes in-house, eliminating the need to outsource complex labeling tasks to third parties. This vertical integration provides tighter control over delivery times and improves overall cost-efficiency.

Quality control and compliance in the 2026 market

The hardware upgrade is supported by a layer of digital quality control and material compliance, which are non-negotiable in today's packaging environment. Both the DIGITAL MASTER 340 and the MASTER M6 utilize TPO-free, UV-curable inks. This ensures full compliance with international food safety ordinances, a critical factor for Supertape to protect and expand its footprint in the food and beverage market.

Furthermore, the presses are integrated with BOBST's AccuCheck and Connect platforms. This digital infrastructure automates calibration and inspection, allowing operators to identify quality deviations instantly without manual intervention. Phil Baldwin, Sales Manager at BOBST, emphasized that the transition required comprehensive training to ensure Supertape's operators could maximize the potential of the new digital and automated workflows.

The Supertape installation serves as a practical case study for the wider converting industry in 2026. It demonstrates that increasing capacity no longer requires adding more iron to the factory floor. Instead, strategic investments in hybrid, highly automated presses can simultaneously shrink a company's hardware footprint, reduce energy waste, and significantly elevate overall equipment effectiveness.