Gallus has launched its first fully digital label press, the Gallus One. Marking a groundbreaking addition to the company’s conventional and hybrid portfolio of label presses, Gallus One has been designed to remove the Total Cost of Ownership (TCO) barrier for the adoption of reel-to-reel digital labels with the highest level of automation and cloud-based technologies. In doing so, it provides brands, for the first time, with access to cost-effective and sustainable, high-quality digital labels.
Gallus One is built on the market-leading Gallus Labelmaster press platform. As a 340mm-wide roll-to-roll UV inkjet digital inline labels press, Gallus One utilises a host of features to achieve high levels of automation and press efficiency, with unrivaled UV inkjet print quality and stand-out print speeds of up to 70 meters per minute. With this, Gallus hopes to reinvent the way in which converters approach digital label printing – providing either a standalone digital offering or a complementary service within an analogue operation.
“With the launch of the Gallus One, we are doing more than just bringing a new press to market – we’re providing a unique solution that has the capability to drive the next big opportunity in labels,” said Gallus Group CEO Dario Urbinati.
“With cloud capabilities built within Gallus One, you can not only enjoy remote set-up but transparent performance monitoring and standardization across your press portfolio and manufacturing sites. In conjunction with the sophisticated press design, the Gallus One offers a complete reel-to-reel digital label solution, including all the software and hardware necessary to produce high-quality, profitable digital labels. All this, with the highest level of automation available, and the most competitive TCO.”
“Within the new Gallus One eco system, users have state of the art inkjet technology, a new ink set, sophisticated workflow software and a new predictive press monitoring service to ensure minimum press downtime. All of these Gallus elements working in harmony has enabled us to dramatically increase press efficiency and productivity.”
Bringing together almost a century of experience in leading the narrow-web industry, together with the invaluable expertise and key resources of Heidelberg, Gallus has capitalised on the strengths of both businesses to develop Gallus One.
For instance, Heidelberg’s ink testing-laboratories developed digital inks specifically for Gallus One’s Fuji Dimatix print heads. Gallus One also integrates fully with the industry standard cloud-based workflow software, Heidelberg Prinect.
Gallus Executive Vice-President, Print, Frank Schaum said: “Gallus One provides customers with a unique opportunity to pioneer a new and complementary category of label service in the quest for significant business growth and differentiation.
“But Gallus One isn’t the only exciting initiative we’re launching today. We are delighted to announce the creation of a new Gallus Experience Centre, currently being built in St Gallen, Switzerland, and expected to open late this year. As part of our vision for realising ‘the label industry of the future’, the new facility has been specifically designed to aid collaboration across the industry.”
Gallus Group, a subsidiary of Heidelberg, has commemorated its 100th anniversary by inaugurating the Gallus Experience Centre in St Gallen. This industry hub serves as a touchpoint for customers, industry experts, stakeholders and the general public. The grand opening welcomed esteemed printers, converters, partners and brand owners as part of the Gallus Experience Days.
Mr Urbinati addressed the increasing global population and the scarcity of labour in the industrial sector, emphasising Gallus and Heidelberg’s commitment digital transformation. He said “smart, connected printing” is key to addressing today’s labour challenges and unlocking revolutionary production automation and manufacturing efficiencies, enabling customers to reduce costs and enhance profitability and sustainability.
Packaging printing, along with label printing, represents one of the printing industry’s strongest growth areas, with an annual global print volume growth rate exceeding 2%. Frank Kropp, R&D Head at Heidelberg, highlighted the significance of Gallus within Heidelberg’s growth strategy, stating that printing volumes are projected to increase from €28billion to €34bn by 2027. Mr Kropp also noted that digital label printing is the fastest-growing segment in the industry, with a projected 6% growth in inkjet-printed labels.
As well as the Gallus One, the group also announced the option to upgrade existing Gallus ECS 340 flexo presses with a digital printing unit (DPU), transforming them into Gallus Labelfire 340 hybrid presses without the need for additional platform investments. Mr Urbinati said this upgrade empowers customers to access the flexibility and versatility of digital printing while leveraging the reliability and precision of conventional printing and further processing technology.
Heidelberg CEO Ludwin Monz expressed his delight in standing alongside the Gallus team and emphasised their unity. With labels and packaging accounting for 50% of the group’s total sales, Mr Monz recognised the significance of Gallus’s digital and automated solutions in shaping Heidelberg’s future. He stated that Gallus is a vital pillar within the company’s growth strategy.
The Gallus Experience Centre also featured guest speakers Katie King, a digital and AI consultant, and Jack Stratten, head of trends at Insider Trends. Ms King discussed the potential benefits of AI, big data, smart connected printing, smart education, smart marketing, smart finance and other advancements transforming various industries. Mr Stratten presented information on changing customer behaviour, specifically highlighting the polarised nature of consumer preferences and the growing importance of sustainability.
Exclusive Interview with Ferdinand, Senior VP, Global Key Accounts & Anchor Shareholder of Gallus
With Gallus celebrating its remarkable 100-year anniversary, Ferdinand Rüesch, Senior Vice-President of Global Key Accounts and Anchor Shareholder of Gallus, shares insights into the company’s journey, technological advancements and the future of label production.
Ben Daniel (BD): Please take us through Gallus’ incredible 100-year history. I believe your family has been involved in the company for three generations.
Ferdinand Rüesch (FR): Absolutely. Gallus’ journey began in 1923, initially manufacturing scales, balances and weight-measure equipment. However, in 1925, we decided to focus solely on weight inspection. Soon after, we received customer requests to build small printing machines for tax and tickets.
The turning point came with the introduction of IBM punch cards, which led us to optimise our production and create machines for the emerging computer industry. My father embraced computer technology early on, implementing office management systems and CAD technology in the late ‘70s and early ‘80s. Our commitment to high precision and reliability attracted attention from government officials, setting us apart from our competitors.
As the printing industry incorporated more electronic components, we introduced our first fully servo-driven printing machine in 1992. This marked a significant transition from purely mechanical machines to those with electronic controls, sensors and reading devices. Eventually, in 2014, when Gallus merged with Heidelberg, we developed the Gallus Label Fire, a hybrid machine that represents the pinnacle of inkjet technology.
BD: That’s an impressive journey! As the industry evolves, what do you envision as the future of label production? Will hybrid presses prevail, or will standalone flexo and digital presses coexist?
FR: Market segments are increasingly specialised. Different product lines require distinct machines. The niches are getting smaller, necessitating dedicated equipment. It’s not a matter of choosing exclusively digital or conventional presses; it depends on the target market.
We offer a range of products to cater to every segment. From fully hybrid machines for complex applications to CMYK digital label production and flexo platforms like the Label Master, we ensure our customers have the right instruments to maximize their profitability and meet market demands.
“It’s the relationship. It’s the performance of the local service. It’s the performance of the machine. It’s the performance of the ink, the paper suppliers, the whole package that makes you successful.” – Ferdinand Rüesch, Senior Vice President, Global Key Accounts, and Anchor Shareholder of Gallus
BD:How do you see the digital technology you’ve recently launched aligning with Gallus’ proven conventional technology? There’s a growing emphasis on digital presses, but your older machines still run remarkably well.
FR: Rather than viewing it as a battle between digital and conventional technologies, I see it as an addition. The choice of machine depends on the profitability and suitability for specific label production. For instance, a printer may use their older Gallus EM280 for 10 jobs and then opt for the G1 digital press for three, maximising profitability. Both digital and conventional presses have their place. It’s not a matter of one technology replacing the other; it’s about utilising the full potential of to meet customer needs.
BD: Finally, what are the keys to success in the industry?
FR: Stay open-minded and actively engage with the market. Instead of solely relying on internet research, visit suppliers and experience centres like ours. Building strong relationships, prioritising local service performance and considering the entire package of offerings – machines, ink, paper suppliers – determines success.
Gallus CEO Dario Urbinati discusses 100 years of history and the new Gallus Experience Center
In an exclusive interview with Ben Daniel of Packaging MEA, Dario Urbinati, CEO of Gallus, sheds light on the company’s remarkable century-long journey and their recent opening of the Gallus Experience Center – a vital hub for the industry, facilitating discussions on challenges and collaborative problem-solving. He also delves into the innovative Gallus One machine and the label fire machine, highlighting Gallus’ commitment to automation and addressing customer needs.
Ben Daniel (BD): Please share with us your perspective on Gallus’ hundred years of history. What does this milestone mean for the company?
Dario Urbinati (DU): Gallus’ rich history spans a century of reinvention and adaptability. I have been fortunate to witness and contribute to a significant part of this journey. Gallus has always embraced change and innovation, positioning itself at the forefront of advancements such as CAD systems and lean manufacturing. The centenary celebration serves as a reflection point and an exciting launchpad for the next 100 years. As CEO, I eagerly look forward to what our technology, people and customer collaborations can achieve in the future.
BD: What is the purpose of this Gallus Experience Center and how does it engage existing and potential clients?
DU: It is a touchpoint for the global narrow-web industry. It originated from an extensive innovation cycle where we engaged with customers to understand their pain-points and challenges. Through this process, we identified significant issues such as labour shortages, input factors, sustainability concerns and industry consolidation. We created a space where industry players can come together, quantify these challenges, and discuss and execute viable solutions. The center facilitates knowledge sharing, testing and experimentation, enabling the industry to collectively move forward.
BD: What makes Gallus One special, and how does it cater to the growing digital space demand?
DU: Gallus One represents a new generation of technology that we developed with our customers. We transformed from a mere machine to an ecosystem, incorporating customers’ insights and needs. Technological building blocks allow us to incorporate new products swiftly and advance technologically. Gallus One prioritises TCO, taking into account factors like energy consumption, footprint, sustainability, uptime and automation. It’s a customer-centric approach, addressing the requirements of a digitalising industry.
BD: Lastly, what message do you have for readers and customers in MEA?=
DU: We value our customers and the extensive installation base we have worldwide, including MEA. We assure them that we have listened attentively to their feedback and are committed to driving the industry forward. Automation is a key focus for us, as we tackle the challenges faced by our customers, including qualified labour shortages. We have developed user-friendly solutions like the Gallus One to make operations easier and more efficient. Additionally, we invite all industry players to visit our Gallus Experience Center, where we can have meaningful conversations, address concerns and collectively shape the future of our industry.
There’s more exciting news for our Middle East customers. We are offering to transform conventional equipment into hybrid solutions. By adding a digital print unit to existing Gallus ECS machines, we turn them into hybrid presses, comparable to our Label Fire. It’s a beautiful opportunity for automation without the full investment burden.
Comments from Biju George, General manager-Sales, Heidelberg Gulf Est,
We value our customers and the extensive installation base we have worldwide, including MEA. We assure them that we have listened attentively to their feedback and are committed to driving the industry forward. Automation is a key focus for us, as we tackle the challenges faced by our customers, including qualified labour shortages. We have developed user-friendly solutions like the Gallus One to make operations easier and more efficient. Additionally, we invite all industry players to visit our Gallus Experience Center, where we can have meaningful conversations, address concerns and collectively shape the future of our industry.
There’s more exciting news for our Middle East customers. We are offering to transform conventional equipment into hybrid solutions. By adding a digital print unit to existing Gallus ECS machines, we turn them into hybrid presses, comparable to our Label Fire. It’s a beautiful opportunity for automation without the full investment burden.
Additionally, we invite all industry players to visit our Gallus Experience Center, where we can have meaningful conversations, address concerns and collectively shape the future of our industry. It’s a beautiful opportunity for automation without the full investment burden.