LabelExpress.eu expands in online label printing with Cartes Gemini laser system

Already present in 18 European countries, the label division of Labo Print increases production quality and efficiency with technology from the Italian manufacturer. Written by Lorenzo Villa

Launched in 2013 with just five employees, Labo Print now has 450 staff and is one of the leading players in digital printing services in Europe, both online and offline. Based in Poznań, halfway between Warsaw and Berlin, the Polish company has made large-format printing its core business, progressively expanding its fleet of printers and cutting/finishing systems. It now offers a vast catalog of products for advertising, communication, interior decoration, and the setup of promotional corners and retail spaces.

The Cartes Gemini laser die-cutting line installed by Labo Print

In 2015, the exponential growth in volumes and revenue led Labo Print to go public, opening up to new investors and international business opportunities. Over the last decade, for example, the company has successfully entered the booming on-demand packaging market, producing and selling custom-printed boxes and paper cups, flexible packaging, and self-adhesive labels. Among these, the label market proved to be the most responsive and promising, prompting Labo Print’s management to establish the LabelExpress division, invest in Durst Tau narrow-web inkjet printers, and adopt laser die-cutting technology. To expand its product range while ensuring lightning-fast delivery times, the company partnered with technical supplier LFP Industrial in January 2024 to purchase a Cartes Gemini laser die-cutting line. LabelExpress particularly appreciated its many exclusive and patented technical solutions. A year later, the results met expectations.

Labels: the crown jewel of a vast catalog

Operating both directly and through several vertical e-shops, including LabelExpress.eu, Labo Print processes tens of thousands of orders per month, exporting its products all over Europe. Thanks to innovative hardware and software technologies, and the combined efforts of its team, the company ensures fast turnaround times and high quality at competitive prices. The product portfolio includes banners, roll-ups, flags, advertising walls, tents, aluminum frames, panels, seating, textiles, custom paper cups, sunshades, and packaging.

Although an increasing number of orders come from the web, Labo Print effectively handles offline jobs thanks to technical sales specialists who assist customers in choosing the right material and advise on file preparation. In addition to catalog items, the company produces all kinds of bespoke projects. Since 2017, the offer has also included self-adhesive labels, which have quickly become bestsellers.

A fully digital production flow

LabelExpress.eu’s explosive growth is driven by the proliferation of brands and products for retail and e-commerce, and by the growing demand for private label products or those adapted for different markets via language changes. Key ingredients of the LabelExpress offer are short turnaround times, high print and finishing quality, and a minimum order of just 500 labels.

“Our standard production time is three working days, but we can fulfill orders in a single day and deliver them precisely when our customers need them,” explains Slawomir Góral, Managing Director of LabelExpress (a division of Labo Print). “This is made possible by a fully digital workflow, allowing us to quickly produce from the customer’s file while eliminating the costs and delays of physical dies.”

Employees at work on the CARTES machine

To meet increasingly diverse demands, LabelExpress offers a wide range of adhesive materials, including smooth and embossed papers resistant to moisture, pearlescent substrates, white and transparent PP films, PET films, and overprintable foils. The combination of finishes, weights, and processing techniques allows the production of a vast array of labels for wine, beer, spirits, honey, food, cosmetics, fruit juices, and all types of bottles, jars, and containers.

The technical advantages of Cartes Gemini

Labo Print’s initial preference for UV inkjet printing and laser die-cutting was driven by the extreme variety of materials, shapes, graphic designs, sizes, and quantities. However, the first years of field experience revealed both the strengths and limitations of these technologies. In laser cutting specifically, the company encountered issues with cut quality and automation and began exploring new options. Among them, Cartes’ platform stood out as the ideal solution.

“Gemini is unique for its range of accessories, modularity, and automation level, and it offers technological features that no one else can provide today,” emphasizes Góral. “Moreover, Cartes is a company that invests early in future technologies, and we’re confident they will support us in our growth.”

With guidance from LFP Industrial consultants, Labo Print selected a Single Semi-sealed® laser head configuration, including the unique ILC® (Invisible Laser Cutting) system, designed to optimize label cutting on dark-colored prints by avoiding visible white edges. They also adopted the IML conveying system, which enables easy production of individual stickers. Thanks to a six-blades slitting group with automatic positioning (Blade Runner) and the ACO (Automatic Change Over) technology with barcode reader, Gemini performs job changes autonomously, processing different orders without having to stop production. At the end of the line, the ATR-360 turret rewinder with automatic cross web-cutting, core gluing and extraction facilitates job separation.

Designed to meet the demands of web-to-print

From left: Krzysztof Fryc of Labo Print, Joanna Zjawin of LFP Industrial, Natalia Tamorina of Cartes, Slawomir Góral of Label Express (division of Labo Print)

For online printers, reducing delivery times and reacting swiftly to unpredictable order volumes is vital. This makes it essential to have flexible technologies that can handle sudden production spikes.

“In developing the latest generations of converting platforms, laser die-cutters, and Jet D-Screen digital embellishment modules, our R&D department considered even the most extreme use cases,” says Natalia Tšamorina, Export Sales Manager at Cartes. “The new dynamics driven by online printing, as well as the specific needs of companies like Labo Print, have presented increasingly complex challenges. These have pushed us to develop platforms like Gemini, which is generating strong interest from both large and small online print providers.”

In addition to the hardware, the combined expertise of Cartes and its partner LFP Industrial in software and integration played a key role in LabelExpress’ success, enabling the quick connection of Gemini to the company’s workflow management systems.

“We already handle over 100,000 orders per year and want to continue growing. The label segment will become increasingly important to us,” states Krzysztof Fryc, CEO of Labo Print. “Cartes offers a one-of-a-kind technology, and LFP Industrial Solutions has been a trusted partner throughout the collaboration—from equipment installation to software consulting.”

Alongside adopting the most advanced and high-performing technologies, Labo Print is also committed to reducing its carbon footprint by producing renewable energy in-house and implementing responsible waste and scrap management practices.