The path to autonomous production

Although drupa 2024 was referred to as 'software drupa', at its core it represented a significant shift towards automated production. In light of the shortage of skilled workers, the increasing complexity of the industry and mounting pressure to improve efficiency and sustainability, one must ask: what will print production look like in four, five or six years' time?

The answer lies in three stages of development: starting with networked automation, progressing to predictive, globally integrated systems and ultimately achieving largely autonomous production, otherwise known as the 'dark factory'. This goal will be achieved gradually and without disruption, and the path is already clearly visible. In this article, we will examine this path in more detail. In our next blog post on this topic, we will discuss strategic decision-making and implementation.

At drupa 2024, networked automation was established as the new norm. What was once only a technological preview has since become a reality in many cases. In sheetfed offset printing, for instance, highly automated systems now handle plate changes, washing processes, and setup procedures with minimal manual input. In digital production lines, print service providers are combining automated pallet logistics with AI-supported quality assurance, particularly for large print runs.

The message is clear: isolated islands of automation are no longer sufficient. What is needed are integrated, networked workflows that are software-controlled, process-oriented and scalable.

To achieve this, systems such as MIS/ERP, prepress, web-to-print and manufacturing must communicate with each other without manual intervention. Initial practical AI functions support production planning and quality assurance. In manufacturing, robots and cobots perform routine tasks in areas such as finishing and logistics. The primary goal is not to replace humans, but to eliminate inefficiencies and enable qualified specialists to focus on higher-value activities.

Once the initial automation stage is complete, the focus shifts from isolated automation solutions to even more integrated processes and improved data quality. The aim is to prevent errors from occurring in the first place. Clean, consolidated data streams form the basis for this. This data must be clearly structured and usable across departments and company boundaries, as well as being accessible at all times.

Cloud-native infrastructure is becoming the norm

Production and business processes are increasingly moving to the cloud. Workflows, ERP systems and web platforms are either becoming cloud-native or at least cloud-enabled. Integrated platforms, known as iPaaS (Integration Platform as a Service), reduce the technical barriers to connecting SaaS tools, online shops, and production facilities. This results in lower costs for individual interfaces and reduced on-site maintenance. Print service providers benefit in two ways: they can scale up without proportionally increasing their infrastructure costs, and they have the flexibility to implement new business models.

From quality control to predictive maintenance

Machine learning is evolving from troubleshooting to early risk detection. Predictive analytics systems use telemetry data from operational machinery to schedule maintenance before production downtime occurs. This increases operational reliability and significantly reduces unplanned downtime. AI-supported assistants are also taking on routine customer service tasks. At the same time, they collect structured data that informs product improvements and optimised workflows.

Highly automated end-to-end (E2E) production lines

Development is accelerating, particularly in inkjet segment. New platforms combined with inline finishing are enabling high-throughput E2E solutions. Book blockers, cutting systems and binding systems are becoming increasingly integrated. Previous transfers and intermediate buffers are no longer necessary. The goal is to achieve continuous production with no downtime between process steps.

The establishment of the 'Talent Pipeline 4.0'

Digital twins and immersive technologies, such as AR, VR and MR, are transforming training. Employees can practise set-up procedures, error scenarios, and maintenance steps virtually, thus eliminating the need to shut down machines. This reduces training times and ensures processes can be reproduced.

This development is strategically crucial, especially given the shortage of skilled workers. Competence becomes scalable and know-how remains within the company, independent of individual availability.

This realises the long-held dream of largely autonomous production, in which machines can operate reliably and independently. This can be achieved regardless of the operator's level of experience.

The ultimate goal is 'zero touch', whereby processes run without manual intervention, from order entry to print production and packaging. The system controls planning, execution and quality assurance around the clock, across shifts and locations.

Generative AI in production

What began in communications is now extending to pre-press and finishing. Generative AI supports the automatic creation of masks for spot varnishes, metallic effects, and other design elements. This enables the creation of custom design variants with minimal effort, making high-quality finishes accessible for smaller print runs. The threshold for high-quality printing is lowered without placing an excessive burden on specialist departments 

Format parity and speed

Digital systems are approaching the performance of classic offset machines ever more closely. However, they have one decisive advantage: personalisation and variety remain possible. In textile production, new high-speed inkjet lines demonstrate how a single operator can handle hundreds of garments per hour automatically, reproducibly and efficiently. Where it makes sense, digital automation replaces analogue processes. Not on principle, but out of operational necessity.

Decentralised production networks

Another aspect of autonomy is geographical flexibility. Cloud platforms can dynamically route print jobs to the nearest qualified production site. The 'sell first, then produce locally' concept reduces inventory and transport costs while minimising the ecological footprint.

Modular all-in-one systems

Automation permeates all stages of print production, from web guiding and printing to finishing and packaging. Combined systems perform several steps in a single pass, such as printing, varnishing, metallising, and die-cutting.

Traditional weak points, such as those found in book or packaging systems, are being eliminated more and more by industrial automation solutions. The focus is shifting from machine speed to optimised material flow throughout the entire system.

The vision of autonomous print production is no longer science fiction. It is becoming a reality. The technological roadmap is clear, moving from networked automation and predictive systems to zero-touch manufacturing. However, technology alone is not enough. Key factors include how print service providers leverage this development strategically, which investments they prioritise, how they prepare their organisation, and the steps they need to take now. In the second part, we will discuss specific action areas, including value creation strategy, sustainability considerations and a staggered investment plan.