Lohmann & AV Flexologic: Drive Automation in Flexographic Printing

The demands on modern flexographic printing processes continue to increase: higher press speeds, maximum precision, and consistent print quality are becoming the industry standard. At the same time, the need for automated workflows that improve efficiency and profitability is growing rapidly. 

New Solutions for Automated Plate Mounting and Increased Process Efficiency

Together with AV Flexologic, Lohmann has developed a solution specifically designed for automated mounting processes in flexographic printing. The goal of the collaboration was to optimize the proven DuploFLEX® plate mounting tapes for the requirements of robotic tape and plate mounting systems.  

Collaboration Focused on Automation 

AV Flexologic is one of the leading providers of automated mounting systems for the flexographic printing industry. During the development of the RoboTAPE and RoboCELL systems, the company was looking for a tape solution capable of delivering both maximum processing precision and reliable print performance. 
 
The collaboration with Lohmann started with initial testing at the company’s headquarters in Neuwied, Germany, and quickly evolved into an international development project involving Lohmann teams in both Germany and the United States. 
“Our shared goal was to develop a solution that meets the demanding requirements of automated processes without compromising print quality,” says Henrik Wass, Global Key Account Manager Graphics at Lohmann. 

Material Innovation for Robotic Mounting Processes

One of the key challenges was adapting the behavior of the mounting tape to the automated application technology used in the RoboTAPE system. Unlike conventional manual applications, the tape in the RoboTAPE process is applied using controlled tension rather than pressure. 
During initial trials, this resulted in small gaps between the wraps on the sleeve, directly affecting process quality. Together with partners, Lohmann therefore developed a modified carrier construction designed to optimize elongation behavior while maintaining the proven print performance characteristics of DuploFLEX®. 
“The RoboTAPE applies the tape using tension, not pressure,” explains Stan Riches, Applications Engineer Manager at Lohmann. “That caused small gaps between the wraps on the sleeve when using our existing foam structure. Working closely with our U.S. foam supplier, we modified the carrier to eliminate elongation – and achieved a perfect wrap.”  

Maximum Precision in Converting

In addition to material optimization, converting precision also proved critical for the automated process. Especially in automated spiral wrapping applications, exact slit roll widths and perfectly smooth edges are essential. Even the smallest deviations can visibly affect the winding result. 
Early trials showed that a variance of just one millimeter could create visible gaps on the sleeve. Based on application footage from AV Flexologic’s test runs, Lohmann’s converting teams in Orange and Hebron fine-tuned the slitting and rewinding processes to meet the exact specifications. 
The result is a highly precise, automation-ready roll configuration specifically designed for repeatable and reliable automated mounting applications. 
 

From Development to a Production-Ready Solution

When the modified tape construction was successfully tested in the RoboTAPE system for the first time, both teams realized they had created something unique — a solution specifically developed for the requirements of automated flexographic printing workflows. 
At the same time, AV Flexologic continued refining the machine's technology on its side. Adjustments to the application head further supported the handling characteristics of the modified tape design and highlighted the collaborative engineering approach behind the project. 
“This project is a great example of what happens when two technical teams challenge each other in the right way,” says Martijn Otten of AV Flexologic. “Automation only succeeds when every detail in the process works together — from the machine design to the tape construction and converting precision. Lohmann’s willingness to adapt, test, and refine alongside our engineers made it possible to turn a complex requirement into a reliable, production-ready solution.” 

Precision and Process Reliability in Focus

The jointly developed solution enables: 

• precise tape application,

• reliable adhesion,

• consistent print results,

• reduced manual intervention,

• increased process stability in flexographic printing.

This helps printers further standardize their production workflows and create the foundation for automated operations.
“For our customers, the value is very clear: more consistency, less manual intervention, and a mounting process that supports higher productivity from the start,” says Martijn Otten, Managing Director of AV Flexologic. “By combining the RoboTAPE technology with an automation-ready Lohmann tape, printers can reduce variation in tape application, minimize rework, and move closer to a fully standardized workflow.”

Sustainability Through More Efficient Processes 

In addition to automation, resource efficiency and sustainability were also key priorities throughout the development process. The optimized roll geometry reduces material waste already during production. At the same time, stable and repeatable mounting processes help minimize setup times, waste, and unplanned downtime.
For printers, this means not only greater process reliability, but also more economical production. “Our goal is to set new standards in flexographic printing — with higher print quality, more efficient processes, and reduced material waste,” says Henrik Wass. “Automation is a key part of that journey.” 

Advancing Automation in Flexographic Printing

The collaboration between Lohmann and AV Flexologic demonstrates how material expertise and machine automation can create new opportunities for the flexographic printing industry.
Both companies see strong potential for future developments — particularly in the area of automated mounting processes and new tape solutions for highly automated production environments.
“We see this collaboration as the beginning of a broader automation roadmap,” says Martijn Otten of AV Flexologic. “As more printers invest in robotic mounting, the materials used in the process need to evolve with the technology.”
By combining material innovation, precision converting, and automated application technology, Lohmann and AV Flexologic are helping pave the way for more efficient and repeatable flexographic printing processes worldwide.