Royal Sens scales production with an automated label bundling solution

When label production grows, manual packing quickly becomes a bottleneck.

Royal Sens experienced this firsthand. The company grew from a family-run lithographic printing business into one of Europe’s leading label producers. Today, Royal Sens operates across four locations in three countries and produces nearly 9 billion wet-glue labels and flexible packaging products every year.

To process these volumes more efficiently, Royal Sens replaced manual paper wrapping with an automated label bundling solution from Bandall.

From manual label packing to automated bundling

For many years, employees wrapped bundles of printed labels by hand using brown paper.

This method worked when production volumes were lower, but it became increasingly inefficient as the company grew. Manual packing required time, labor, and physical effort. It also limited the company’s ability to increase capacity without adding more people to the process.

Royal Sens needed a scalable way to bundle printed labels directly after production.

The solution was automated banding.

Bundling labels directly after production

Royal Sens integrated a Bandall label banding system into a newly developed packaging line.

After printing and cutting, the labels are automatically grouped into stacks on a conveyor. The banding machine then applies a paper band around each stack, creating secure and clearly defined bundles.

Most bundles contain 1,000 labels. Depending on the paper thickness and order requirements, Royal Sens can also create bundles of 750 or 1,250 labels.

This allows Royal Sens to combine label stacking, bundling, and packing into a single automated production flow.

A label bundling solution built for higher volumes

By automating the bundling of labels, Royal Sens transformed a repetitive manual process into a consistent and scalable operation.

The automated label bundling system helps Royal Sens:

• Reduce manual label packing
• Process higher production volumes
• Create consistent bundle quantities
• Improve post-press efficiency
• Reduce the physical workload for employees
• Use less packaging material
• Prepare the line for further automation

Because the labels are bundled immediately after printing and cutting, fewer manual handling steps are required before storage or delivery.

Using less material to package printed labels

Before banding, bundles of labels were fully wrapped in sheets of brown paper.

A paper band only secures the stack where material is needed. This significantly reduces the amount of packaging used for each bundle.

The paper bands are also easy for customers to remove and place in the appropriate recycling stream. This creates less packaging waste and simplifies unpacking.

For Royal Sens, banding provides a practical way to improve both production efficiency and packaging sustainability.

A reliable solution for daily production

For a system to remain valuable over time, the machine itself is only part of the equation. Ease of operation, maintenance, and dependable service are equally important in a high-volume production environment.

"The machines are easy to operate, and Bandall is a reliable partner for maintenance and service. It’s been a great collaboration."

— Production manager Abdel

Royal Sens has used Bandall systems for decades, allowing its label bundling process to develop alongside the company’s production requirements.

Ready for the next stage of automation

Royal Sens continues to invest in its future. Planned developments include automatic stackers, robotic arms and further increases in production capacity.

Because banding can be integrated with conveyors, stacking systems and other production equipment, the solution can grow alongside the packaging line.

“As we continue to scale up, we will definitely choose Bandall’s automatic banding machines again. We highly recommend Bandall.”

— Abdel, Production Manager at Royal Sens