Optimize or Fall Behind
Automation is no longer just a ‘nice to have’ option in your operation — it’s a critical tool that makes the difference between profitability and closing the doors.
Automation isn’t anything new. From software to hardware, it has been creeping into every element of print and graphics for a few years now, improving efficiency and productivity for all those who took the leap. But as we move into 2025, automation is no longer just a nice option — it is a must-have for any shop that wants to not just be profitable but to simply stay in business.
That said, while automation has become deeply rooted in many segments of the industry, wide-format, in particular, has seen slower, more sporadic adoption.
“The current state of automation in wide-format printing is highly varied and scattered, with a wide range of implementation levels depending on the company,” says Piet De Pauw, head of marketing at Enfocus. “Some businesses are still operating entirely manually, relying on human labor for every step of the process, from prepress and printing to finishing. On the other hand, there are highly advanced operations where automation has reached levels that include the use of robots and cobots (collaborative robots) to handle tasks like material feeding, unloading, or even assembly.”
These companies, he says, leverage cutting-edge technologies, integrating software and hardware to optimize efficiency, reduce errors, and boost productivity.
“One thing is certain,” notes David Lunardi, vice president of sales, OneVision, “the entire industry now realizes that there is no alternative to automation if you want to remain competitive and successfully address the current shortage of skilled workers.”
But what is holding wide-format back from the same automation adoption driving other print businesses forward?
Debra Hobden, global marketing director at PrintFactory, has a few ideas. She notes, “One of the biggest hurdles in automating wide-format equipment is the lack of standardization. Each print shop operates differently, with unique equipment, substrates, and customer demands. Bridging these variations requires adaptable and scalable automation solutions, which can be costly and complex to develop.”
Additionally, she says the initial investment in automation technology can be a barrier, particularly for smaller businesses. Many printers are hesitant to invest without clear evidence of a strong ROI.
That lack of standardization is the same hurdle De Pauw is watching, as he notes, “Wide-format printing encompasses everything from banners and vehicle wraps to custom signs and exhibition displays, often involving different materials, sizes, finishes, and quantities. This variability makes it challenging to standardize and automate processes effectively.” He says one common misconception among wide-format printers is that automation isn’t feasible for their unique jobs, especially when dealing with single-unit runs or highly customized orders. While many believe that the setup time and complexity negate the benefits of automation, this is not the case.”
But it’s not all bad news. In fact, in the past 18 months, the segment has seen major strides forward when it comes to automating wide-format work.
1. Better software.
All three experts agree automation software has seen significant leaps forward when it comes to the wide-format side of print. Preflighting, nesting, and color management are areas print software vendors have focused on, and the result is powerful tools that take into account the variability of wide-format jobs, allowing many previously manual tasks to be automated.
2. The AI revolution.
On the heels of better software tools has been the explosion of AI into every facet of life and business. And wide-format printing is no exception. While it is most common today in more business-automation related tasks, such as analyzing workflow to make better decisions for aspects such as investments or which customers or jobs will be most profitable, it has also started to trickle into production areas, such as prepress, helping not just automate tasks but anticipate — and even fix — problems before a human ever sees them.
AI is also making its way more and more into wide-format hardware, with many presses today coming with powerful onboard AI capabilities that monitor that monitor maintenance needs, when to take care of tasks with the least amount of downtime and automatic adjustments “on the fly” to manage capacity and optimize print times.
And it’s just the beginning. As AI continues to mature and grow, we’ll see more powerful applications that we can’t even conceive of today.
3. Robotics.
Increasingly, robots are making their way onto print shop floors — including wide-format. While they tend to be fairly simple machines, made to handle repetitive tasks such as loading and unloading sheets, thus freeing up personnel to do more creative and complex tasks, some companies are starting to roll out autonomous units capable of interfacing directly with the presses to deliver and load the correct substrates from the warehouse to the press, at the right times, exactly when needed for the job to run. They can then take the printed jobs and move them to the next stage of the process, to be finished or prepped for shipping or installation.
One common misconception among wide-format printers is that automation isn’t feasible for their unique jobs, especially when dealing with single-unit runs or highly customized orders.
One key point to note here is that in all of these cases, it’s not just the hardware or software alone that achieves the kind of automation that will be required going forward.
“Both software and hardware play critical roles in the future of wide-format automation. Only when they are integrated and working together in a smooth production process will automation be truly successful,” says Lunardi.
De Pauw agrees, noting, “The future of wide-format automation lies in a combination of software and hardware, as the two complement each other to maximize efficiency and productivity.” Robotics, such as robotic arms, he says, are already enabling one operator to oversee multiple production machines by automating material handling, loading, and unloading.
However, these machines still need to be fed with a steady stream of well-prepared jobs, and that’s where software becomes indispensable.
Workflow automation software ensures that jobs are optimized, preflighted, and queued correctly, to feed production lines without bottlenecks. It also provides the operational intelligence to manage complex schedules and track progress, which is essential when managing multiple machines. Additionally, the investment required for software is significantly lower than for robotics, making it the entry point for many companies starting their automation journey.
Over time, however, combining software and hardware will allow wide-format printers to scale their operations efficiently while maintaining flexibility for diverse job requirements.
Further, Ramona Serafino, product marketing manager, Wide Format, FUJIFILM North America Corporation, Graphic Communication Division, notes that automation hasn’t just improved, it’s also expanded to far more elements in the shop. She notes, “The biggest improvements to wide-format automation in the last 12-18 months seem to have been not only the expansion of automation options to include more mid-range wide-format solutions but bringing more awareness to end users about available software automation options.” She adds that these improvements have allowed print service providers to not only meet their customers’ needs in a timely and cost-effective manner but also free up some bandwidth to increase their product offerings.
“Both software and hardware automation are the future of the wide-format space,” Serafino says. “Utilizing automation will only help print service providers meet the ever-expanding demands of the wide-format industry.” Additionally, she says streamlining operations brings cost savings to their business for various reasons. Some of these factors include, but are not limited to, operating with fewer people, quicker and more effective order taking and estimating, and less waste due to software automations that can help maximize media sizes and set up jobs.
What's Next?
That’s the state of wide-format automation today. But where will it go in the next year? Two years? The next decade?
Hobden notes that there are a few areas she sees as the ones to watch in the next 12-18 months, in particular. “The industry should focus on scalable automation solutions that cater to a wide range of print shop sizes and needs. Smaller businesses, in particular, will benefit from modular solutions that allow incremental upgrades.” She also stresses that AI and machine learning, greater interconnectivity between disparate systems, and automation focused on sustainability, in particular, are all things she expects to have a major impact on the segment in 2025.
Lunardi concurs, noting, “Over the next 12-18 months, I think we can expect to see more AI capabilities. Automation tools will become smarter, predicting problems before they occur and adjusting settings without human intervention. More seamless integration of software and hardware in workflows, and the use of API-based solutions and cloud systems will enable a more connected production environment.” Of course, he says, the use of robotics (e.g., for post-print handling) will increase. Keeping track of how AI can improve decision-making and optimize workflows will be critical, as will adapting to emerging standards in automation integration.
It can feel overwhelming to find where to start investing in automation, given the fast pace of change. After all, no one wants to invest heavily in new hardware or software only to see it obsolete in six months.
Lunardi continues, “For printers looking to streamline and automate their wide-format business, implementing flexible automation software can be transformative. The key is to focus on end-to-end automation that reduces manual intervention, improves efficiency, and minimizes errors.”
Hobden goes further, offering her top four tips for wide-format printers looking to embrace automation:
1. Start with Workflow Automation: Automate prepress tasks first, as these often provide the quickest ROI and lay the groundwork for further automation.
2. Invest in Training: Ensure your team understands how to maximize automation tools. Even the best systems require skilled operators to achieve their full potential.
3. Partner with Trusted Vendors: Choose technology partners who offer comprehensive support, from installation to ongoing maintenance.
4. Prioritize Scalability: Look for solutions that can grow with your business to avoid costly replacements down the line.
“I would encourage print service providers to look at all automation offerings available and then to prioritize based on the business needs,” advises Serafino. “There are a lot of great options out in the market and some have features that might overlap with what the end user already has, or there might be a more effective solution to replace the end user’s current system.”
Ultimately, automation isn’t a luxury — it is a necessity for those looking to do business in today’s industry. Embracing software automation as the first step down that road is a great place to start, then building it out and connecting more equipment and systems over time. This would be followed by adding hardware automation where it makes sense, removing manual touchpoints and freeing up staff to do the creative, innovative, and interesting parts of the job while the robots take care of the repetitive tasks no one enjoys.
People and robots working seamlessly together to produce compelling, innovative, and unique wide-format projects might sound like a science fiction fantasy. But that vision is already shaping today’s reality, and those who don’t embrace it will be left behind.
