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Taylor Prime Labels & Packaging Streamlines Flexo Plate Production with Esko Hardware

Taylor Prime Labels & Packaging, an engineer of printed products, digital services, and integrated technology, overcame flexo platemaking challenges with Esko hardware and software solutions.

Taylor Prime

The Challenge:

Ongoing challenges with consistency and repeatability in plate performance. Deviations across production runs impacted quality and efficiency.

The Solution:

The Benefits:

Improvements in plate quality and consistency, reduced makeready times, and extended plate life—enabling flawless solids, pinhole-free coverage, and cleaner highlight dots across every job.

Case Study Summary

Using Esko CDI Crystal, XPS Crystal, and Digital Flexo Suite, Taylor Prime Labels & Packaging has dramatically improved their platemaking process. From faster press setups to more consistent print quality, Esko integrated solutions have empowered Taylor Prime Labels & Packaging to overcome previous limitations and scale with confidence.

The partnership extends beyond tools. It’s built on a foundation of trust, support, and a shared commitment to innovation.

Learn more about XPS Crystal

“Consistency and repeatability were some of our biggest challenges. The CDI Crystal and XPS Crystal have eliminated all our consistency issues with undeviating performance plate after plate.”

Scott Kleven - Prepress and Projects Manager, Taylor Prime Labels & Packaging

High Volume, Low Consistency

Taylor Prime Labels & Packaging operates five production plants across the United States, delivering high-quality labels and flexible packaging. Print volumes range from runs as small as 250 labels into the millions.

Despite their impressive scale and range, they faced critical challenges in flexo platemaking—particularly around consistency and repeatability.

According to Scott Kleven, Prepress and Projects Manager, their existing equipment was limited by aging infrastructure and format constraints. Therefore, it was unable to accommodate newer screening technologies, or the high volume of plate production required.

Taylor Prime Labels & Packaging needed to upgrade their equipment for their business to grow. After comparing Esko solutions to other offerings, and having worked with Esko in the past, Taylor Prime Labels & Packaging selected Esko as the best solution for their current and future needs.

“Esko checked all the boxes for what we were looking for. The hardware is reliable and produces consistent results plate after plate. The screening options in the software offered solutions for all our different print technologies.”

Scott Kleven - Prepress and Projects Manager, Taylor Prime Labels & Packaging

Consistent Plates, Cleaner Prints

Upon implementing Esko CDI Crystal and XPS Crystal, along with the Digital Flexo Suite, Taylor Prime Labels & Packaging’s plate issues have been diminished by the enhanced plate quality and consistency. Additionally, press makeready times have improved and plate life has exceeded their expectations.

“The XPS’s ability to produce consistent and reliable dots time after time helps ensure the print results are repeatable each time you put a job on press.”

Scott Kleven - Prepress and Projects Manager, Taylor Prime Labels & Packaging

The Esko hardware now plays a critical role in their daily operations, providing plates to their presses across 3 facilities. Furthermore, Taylor Prime Labels & Packaging’s process has been streamlined. Plates are now moved around less, eliminating operator errors and plate remakes.

Print quality has notably improved, with advanced screening eliminating pinholes, boosting ink density, and enabling smooth gradient fades—all driven by the XPS Crystal’s reliable dot reproduction and repeatable performance on press.

“Esko has a great vision for the future of platemaking and is working to streamline plate processes, putting a focus on automation to eliminate waste and increase productivity in the plate room and at press.”

Scott Kleven - Prepress and Projects Manager, Taylor Prime Labels & Packaging

Looking Ahead

As Taylor Prime Labels & Packaging continues to optimize their operations, they plan to increase process automation to eliminate touch points as much as possible and improve efficiency.

“Esko has been a great technology partner. The people and resources they have available when I need a solution to a problem are what I value most.”

Scott Kleven - Prepress and Projects Manager, Taylor Prime Labels & Packaging

For more information about how the entire Crystal line and Digital Flexo Suite can help your business, click here.

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