BY KATIE FORSYTHE
When your customer orders custom labels, they expect consistent quality, fast turnaround, and reliable performance on your packaging lines. But behind the scenes, the type of printing press used can make a big difference in the final product they receive. Flexographic printing is a leading method for producing high volumes of labels efficiently–and it comes in two main presses: gear-driven and servo-driven. While both produce excellent labels, the technology powering the press can impact everything from print clarity to delivery time and even your customer’s overall cost.
Gear-driven flexo presses use mechanical gears to control how the label material moves through the press. On a gear-driven flexographic press, registration is controlled mechanically, so any misalignment between colors or print stations must be corrected manually by the press operator. These systems have been trusted in the label industry for decades. Here's what this means for you and your customers:
For running large quantities of the same design, a gear-driven press can help keep production costs lower.
These presses are built for long runs with minimal interruption, ensuring dependable delivery times.
Servo-driven presses use computerized motors to control each print and die-cutting station independently. This allows for much tighter control and real-time adjustments during production. The digital precision allows the press to quickly achieve and maintain perfect alignment between colors and stations, reducing setup time, minimizing waste, and ensuring consistent print quality from start to finish. Here's what this means for you and your customers:
With tighter registration control, your labels–especially those with fine detail or multiple colors–come out crisp and aligned every time.
Setup time is reduced, which helps speed up production and meet tight deadlines.
As the distributor, knowing the different types of presses available can help you find the right labels for your customer’s needs. Here are some considerations:
Gear-driven: Often more economical for basic, high-volume labels where cost control is the top priority.
Servo-driven: Can reduce waste, reprints, and downtime—ideal for brands where quality and precision matter most.
Gear-driven: Can produce more material waste during registration and changeovers, which may be a consideration for sustainability-minded brands.
Servo-driven: More efficient registration reduces label waste during setup, helping support eco-friendly goals.
Gear-driven: Excellent for simpler designs where precision is still important but not critical.
Servo-driven: Ideal for premium packaging, detailed graphics, and color-critical designs.
Gear-driven: Reliable over long runs but may need manual adjustments to maintain consistency on complex jobs.
Servo-driven: Delivers easy repeatability–your customer's labels look the same every time, even across large runs.
Gear-driven: Occasional longer lead times due to more involved setup and calibration.
Servo-driven: Faster setup and fewer manual adjustments mean quicker turnarounds.
Your customer's label design, application, and order volume should help determine which press technology is the better fit for their project. Is your customer is looking for simple, single- or two-color labels for high-volume packaging? A gear-driven press is an efficient, cost-effective choice. Color-critical labels for consumer goods, health products, or premium packaging? A servo-driven press offers the registration and detail they need for maximum visual impact.
The type of flexographic press used to produce your customer’s labels directly affects quality, consistency, turnaround time, and value. At the end of the day, it’s not just about the technology–it’s about delivering the right labels for your customer’s product, timeline, and budget. Need help choosing the best option? Talk with our team today–we’ll match your needs with the right press technology to ensure your customer's labels perform flawlessly from press to shelf.