Automation meets innovation
How AV Flexologic and Lohmann set a new standard in flexographic printing
Strong Partners for Smarter Printing
What began as a technical challenge evolved into a strong partnership between AV Flexologic, one of the leading specialists in automatic plate mounting equipment, and Lohmann, the “FLEXperts” behind the renowned DuploFLEX® plate mounting tapes.
AV Flexologic has been collaborating with various tape manufacturers to optimize the performance of its fully automatic RoboTAPE / RoboCELL system. “Together with AV Flexologic we started working on meeting the specific requirements of the Robotaper.” recalls Henrik Wass, Global Key Account Manager Graphics at Lohmann. “Our partners at AV Flexologic first approached Lohmann’s Neuwied headquarters to run initial tests with DuploFLEX®; later, a conversation at a U.S. trade show about the RoboCELL system reignited the dialogue and brought Lohmann’s global teams (Neuwied, Orange, U.S.) together to explore a path forward.”
Making the Impossible Possible
Instead of accepting the technical barrier, Lohmann’s FLEXperts took it as an invitation to innovate. Following a joint review of the first test results in a Teams meeting, Lohmann U.S. took the lead on the tape modification, coordinating directly with the foam supplier to implement the carrier change while safeguarding DuploFLEX®’s print performance. Together with AV Flexologic and key suppliers, the team developed a unique tape construction that retained Lohmann’s characteristic print advantages while meeting the mechanical requirements of the robotic mounting process. By coordinating directly with the foam supplier, they implemented the carrier change while safeguarding DuploFLEX's print performance.
“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.”
In parallel, converting precision proved crucial for automated application: the spiral wrap requires exact slit roll widths and perfectly smooth edges. Early trials showed that even a 1 mm variance could create a visible gap on the sleeve. After sharing application footage from AV Flexologic, Lohmann’s converting teams in Orange and Hebron tuned slitting and rewinding to the specifications – delivering repeatable, automation-ready rolls.
When the modified tape was first tested at AV Flexologic, both teams knew they had achieved something unique: a tape design exclusive to Lohmann, perfectly compatible with the RoboTAPE system. On AV Flexologic’s side, engineering refinements – including a new application head better suited to the adjusted tape behavior – underlined the truly collaborative nature of the solution.
“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.”
A Perfect Match for Automation
AV Flexologic is currently the only company offering a fully automated plate and tape mounting system for the flexographic industry – and Lohmann now provides a unique product range that unlocks the full potential of this technology.
The result: a solution that ensures precise application, stable adhesion, and consistent print quality – key prerequisites for automated workflows in flexographic printing.
“This cooperation shows what’s possible when both sides share expertise and think beyond traditional solutions,” says Henrik Wass. “It’s not just about compatibility – it’s about performance, efficiency, and helping printers run more profitably.”
Momentum also grew through live demonstrations at drupa 2024 (Düsseldorf), where AV Flexologic showcased RoboCELL with DuploFLEX®; visitors highlighted the precise conversion quality and smooth, reliable application during the demos.
“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. That is exactly where the industry is heading — smarter, faster, and more predictable flexographic production.”
Innovation Driving Sustainability and Profitability
The project highlights Lohmann’s approach to innovation as an enabler for sustainable progress. The new tape design helps reduce waste, minimize downtime, and improve plate life – all factors that contribute to lower resource consumption and higher customer profitability.
“Our goal is to set a new standard for excellence in flexographic printing,” says Henrik Wass. “That means sharper print images, faster press speeds, less waste – and a clear advantage for customers who are ready to move toward automation.”
Sustainability benefits start at production: the required RoboTAPE roll size allows Lohmann to slit an even number of rolls from each master log without offcuts, eliminating material waste. In operation, improved process stability further reduces printing waste and non-productive time.
Looking Ahead
With automation continuing to reshape the flexographic printing process, both partners see great potential in expanding their collaboration. Future projects are already being discussed, combining AV Flexologic’s robotic expertise with Lohmann’s material innovation.
Beyond the foam-based construction, Lohmann has also validated filmic mounting options (e.g., 0.10 mm on compressible sleeves) where the RoboTAPE’s rigidity advantages are evident – pointing to a broader portfolio of automation-compatible tapes. In the field, Lohmann continues to coordinate with AV Flexologic’s sales teams to identify opportunities at printers already running RoboCELL and related systems.
“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. Together with Lohmann, we are looking at future tape solutions and application possibilities that can make automated flexo production even more efficient, sustainable, and accessible for converters worldwide.”
“Why settle for what has always been done?” concludes Henrik Wass. “We’re here to innovate – to help our customers differentiate, automate, and succeed.”
Smart Bonding Solutions for Flexo Printing | Lohmann