In this article Phil Jackman (L) and Simon Daplyn (R) from Sun Chemical explain about the importance of ink with unlocking new possibilities for digital inkjet printing.

Digital inkjet technologies are taking the global print marketplace by storm, especially as the need for shorter runs of print and personalization increases. With the digital print market estimated to reach $225 billion globally by 2029, businesses are seeking to implement digital print technology into their operations to achieve productivity and profitability gains – but the challenge is often where to start when considering a new application.

It’s great to identify a need for digital printing within an operations process, but where is the best place to start and who is the decision-maker? It could be the system provider or even printhead manufacturer. Another question to consider is whether or not choosing the right ink the main priority. For many, the printer carries the highest capital investment and so is working with the printer may be first step, but for others the printhead drives the decision. When looking at adopting digital inkjet for the first time in an industrial application, there are several factors to take into consideration.

1. The importance of ink chemistry

The range of available chemistries and ink technologies has evolved greatly, in parallel with the advances in hardware that have made inkjet a viable industrial print method, along with the possibility to print at high speed with excellent reliability and system up-time. Advancements in printheads with different nozzle configurations and densities, widths and print frequencies have contributed to increasing the speed, quality and efficiency of the digital print process. In many emerging applications, the print quality and requirements of the head are a primary consideration. For example, high-quality packaging markets may require 1200dpi resolution to meet the demands of the market and brands for text and detail and need to meet other application requirements like speed, maintenance, ease of changeover. This means that many businesses look at the choice of printhead and system first and try to match the ink chemistry, software and ink delivery systems afterwards.

Although the hardware is, undoubtedly, critical for the delivery of the ink, it is often prudent to understand the ink chemistry and match to the hardware rather than visa versa. If the hardware restricts the ink chemistry from achieving the end products’ application performance and quality, the print solution will never achieve its optimum, so getting the choice of ink right is a critical step in the adoption of a digital printing process.

Once a product is printed, the role of the hardware is essentially complete while the ink has just started its lifecycle. Ultimately, the ink itself defines both performance and the acceptance of the print and application, and its chemistry should ideally be a primary consideration in any discussion of digital technology adoption, from ink wetting, adhesion, and application performance to product compliance. The choice of ink will also have a significant impact on the drying speed and technology, and therefore, the overall throughput potential of a system. After printing, the ink is part of the finished product and must meet brand standards, environmental legislation, and more, and must demonstrate its place in a circular economy.

2. Identify the right type of ink

In markets with evolving regulatory requirements, the ink type itself can be critical as well. For instance, with a growing focus on sustainability, there has been an increased demand for water-based solutions with a view to reducing the environmental impact of the print process without compromising quality and consistency. This selection is critical, but a water-based ink does not automatically result in a low-impact and sustainable solution. Instead, it is about selecting the right chemistry and process overall. The ink type chosen directly affects the implementation process. For example, by choosing a water-based ink, several hardware options are automatically ruled out in terms of printhead and drying/fixation. The type of ink chosen will also dictate substrate compatibility and whether or not there is a need for a priming stage prior to printing.

3. Collaboration is key

For many industrial applications, it can be difficult to find an off-the-shelf solution to meet all of the technical requirements. In many instances, industrial printers are looking to add a digital ink printing capability to an existing production line and, even when an offline printer is acceptable, the full end-to-end process may require something non-standard. For this, there is a whole eco-system of inkjet enablers that are critical to the success or failure of a project. It is fair to say that if one part of the process is not optimal, the whole workflow is impacted. For this reason, it is essential for clear collaborations to ensure the system, printhead, electronics, print software, substrate handling, drying and ink technologies work together in harmony to produce the end result.

Start the digital printing journey today

Although digital printing is often seen as the ‘next step’ for industrial printers, it can be a challenging process to implement and ensuring a ‘right start’ can often dictate future success. While it is tempting to consider the printer as the most important factor, the choice of ink chemistry and therefore, the printhead, can often be more critical to success. Ultimately, if the ideal ink does not fit in terms of press design or function, the printer cannot improve the result enough to compensate. An ideal scenario would be to discuss requirements with ink and printhead manufacturers simultaneously, allowing close collaboration to optimize the properties of the ink. This ensures maximum performance, shorter development time, and ultimately a fully integrated solution.

Sun Chemical has more than 30 years of experience in developing digital inks across a range of chemistries. This combined with an extensive knowledge of regulatory and quality requirements, distilled from industry understanding as the number one provider of conventional printing inks, makes us the perfect partner for businesses seeking to explore digital printing in their industrial applications.

Author Contacts:

Simon Daplyn

Manager, Product Marketing

simon.daplyn@sunchemical.com

Phil Jackman

Global Product Manager

phil.jackman@sunchemical.com

Sun Chemical Corporation is a subsidiary of Sun Chemical Group Coöperatief U.A., the Netherlands, and is headquartered in Parsippany, New Jersey, U.S.A. For more information