Guillermo Rodriguez, Global Sales Director at AV Flexologic, on Operator Dependency, Automation, and the Future of Flexo Prepress

Flexographic printing has seen continuous investment in speed, materials, and press technology but according to Guillermo Rodriguez, Global Sales Director at AV Flexologic, the real limitations in production are not happening at the press. They are happening before it. In this interview, we explore the key challenges converters face today, the shift toward automation, and what it actually takes to build efficient, scalable prepress and mounting workflows. 

The Industry’s Most Persistent Challenge: Operator Dependency 

One of the most persistent challenges in flexographic operations is the heavy reliance on operator skill, where output can vary significantly between shifts due to differences in experience and expertise. This issue is further compounded by the growing difficulty in hiring and training qualified personnel, as labor shortages continue to impact the industry. 

As a result, production environments often lack full control over output quality. Instead of being driven by consistent, repeatable processes, results tend to fluctuate depending on who is operating the equipment at any given time. 

Mounting Errors: The Hidden Driver of Waste and Downtime ​

This variability has direct and measurable consequences across the production process. Mounting inaccuracies do not just affect quality in isolation; they lead to press downtime, increased material waste, and the need for rework, all of which reduce overall efficiency. 

These are not occasional disruptions but recurring issues that become embedded in daily operations when processes rely heavily on manual input. Over time, this results in a continuous loss of time and resources, much of which goes unnoticed or is accepted as part of normal production, despite its significant impact on performance. 

A Clear Shift Toward Autonomous Workflows 

The industry is now moving beyond traditional automation, with the focus shifting toward significantly reducing, and in some cases eliminating, operator involvement altogether. Rather than simply assisting operators, new technologies are designed to take over critical steps in the process, improving consistency and reducing the risk of human error. Three developments are driving this change:  

One of the key developments driving this change is the adoption of image recognition for plate alignment. Instead of relying on manual positioning, systems are now capable of automatically detecting and aligning plates with a high level of precision, reducing dependence on operator judgment and enabling more repeatable, accurate results. 

Another important development is the reduction of setup parameters within modern systems. Machines are increasingly being designed to require fewer inputs from operators, simplifying the setup process and minimizing the number of decisions that need to be made manually. By reducing the level of human intervention, the risk of errors decreases, resulting in more consistent and reliable production outcomes. 

Lastly, critical development is the integration between prepress and mounting, where data is transferred directly between departments rather than being handled manually. This allows setup parameters to be defined upstream and executed consistently during mounting, reducing the need for operator interpretation and intervention. As a result, processes become more standardized, and variability is significantly reduced. This level of integration is increasingly essential for achieving predictable, repeatable results across production.

Why Technology Alone Is Not Enough ​

Investing in automation does not automatically guarantee improved performance. According to Guillermo Rodriguez, success depends on two critical factors that go beyond the technology itself. 

The first is transparency in expectations. It is essential to clearly define what a solution is intended to achieve from the outset, including its scope, limitations, and expected impact. When expectations are not aligned early on, even well-designed systems can fall short of delivering meaningful results. 

The second is long-term support and commitment. The value of a system is not realized at the moment of installation but develops over time through continuous optimization, ongoing support, and process refinement. Without this sustained engagement, even advanced technologies are unlikely to reach their full potential. 

What This Means for Converters ​

The next phase of flexographic printing will not be defined by faster presses, but by the level of control manufacturers have over their processes. As production environments become more complex, consistency and predictability are becoming the true differentiators. 

Converters that reduce operator dependency and connect their workflows will be able to achieve greater consistency, lower levels of waste, and improved overall efficiency. In contrast, those that continue to rely heavily on manual processes are likely to face increasing limitations, as variability and complexity make it more difficult to maintain stable, high-quality output.