First Point of Contact Overlaminates for Floor Graphics
by Melissa Donovan
Floor graphic media is evolving. The application’s popularity has ebbed and flowed thanks to massive interest during the COVID-19 pandemic. In the aftermath, media manufacturers confront the issues raised during that time, namely when to use the right product. One that offers safety, durability, and high visual quality.
There are two options—one versus two step. A one-step system involves a durable media while two-step systems include a combination of media and overlaminate. While the advantages of a one-step process are evident, twostep floor graphic systems also have their benefits.
“The advantage of a two-step product is that you can select the laminate texture level with the adhesive strength needed for your application. For example, an end user needs trade
show graphics throughout the venue. The print service provider (PSP) can offer graphics for indoors that will work with the tile or carpet and then outdoor sidewalks as well. Also, printing directly to the print media allows for a clearer design over a slip-resistant texture with the one-step product,” explains Amanda Smith, marketing and communication manager, Mactac.
The overlaminate portion of a two-step system carries heavy responsibility. Being the first point of contact, it must feature a certain level of traction to ensure slip resistance. In addition, it should protect the graphic underneath from scruffs, tears, and stains.
What to Look For
There are two materials that need to be considered for twostep floor graphic systems—the base media and the laminate. For the overlaminate, some factors to look
There are degrees of non-slip ratings and it’s important to match the rating with the application.
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— Michael Richardson, business development manager, Jessup
1) ICON TL-6100 from Substance Incorporated is a durable, 6-mil textured anti-slip overlaminate for floor graphics. 2) For Drytac, Polar Grip paired with its overlaminate solutions offers a longer term, sliprated option for floor graphics.
into include safety considerations, clarity, thickness, material type, and material construction.
The overlaminate plays an important role in the two-part system. “The ‘tread’ of a textured overlaminate allows for direct foot traffic and offers slip resistance,” notes Sam Crosby, dealer manager, Graphic Finishing Partners, LLC.
“The lamination choice is paramount to the intended graphic working in pedestrian foot traffic areas without causing liability issues from slipping and falling. To this point, a few specifics need to be addressed with material choices regarding field requirements,” explains Dennis Leblanc, senior business development manager, North America, Drytac.
Top of mind is safety certifications, which range from anti-slip/trip to fire safety. “Anti-slip ratings are a must for floor graphic applications, next to certifications,” adheres Rene Bourgeois, VP sales North America, ASLAN Selbstklebefolien GmbH. Anti-slip includes those from ANSI, DIN, and BS, as well as fire safety rating DIN EN 13501-1.
“There are degrees of non-slip ratings and it’s important to match the rating with the application. For example, if the product is used outdoors, a wet slip rating is important, as the chances of the graphic getting wet from rain are high,” explains Michael Richardson, business development manager, Jessup Manufacturing Co.
The second most important feature is the clarity of the laminate, followed by material type and
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thickness, and then UV resistance, according to Richardson. “The clarity of the laminate should not interfere with the ‘pop’ of the image. Depending on the desired duration of the ground/floor graphic, the material type and thickness is important. For long-term durable warehouse floor graphics, choose a thicker PVC or polycarbonate. For a short-term durability—less than three months—a thinner film could be used. If the graphic is exposed to direct sunlight, then UV resistance is an important feature.”
Bryan Baab, product development manager - wide format and Evan Rezin, product manager - wide format, Nekoosa, agree on clarity being one of two critical aspects to consider for overlaminates beyond anti-slip. The second is that “the overlaminate must protect the graphics from foot traffic for at least six months.”
When it comes to type of material, Edwin Ramos, director of sales, GBC, ACCO Brands, says a textured
polycarbonate is preferred for its robustness and ability to hold up well in high-traffic areas.
“Due to the nature of floor graphics, the majority are short term, which makes calendered PVC an economical and durable choice,” suggests Daniel Velez, VP of sales, Substance Incorporated.
According to Baab and Rezin, customers request sustainable materials to reduce their environmental impact, which is why Nekoosa just launched a polyolefin floor graphic overlaminate. “Traditionally, overlaminate films were produced with very thick—greater than 5-mil—textured vinyl film. Interestingly, the same durability and anti-slip properties can be achieved with new, non-PVC films at a lower cost.”
In terms of thickness, “the thicker the overlaminate, the more it will stand up to foot traffic and wear. That is because thicker laminates hold up better to scuffing and actually make the graphic easier to install,” explains Joey Heiob, technical service representative, Avery Dennison Graphics Solutions.
“Floor graphic laminates range from 3- to 19-mil. The 6-mil range is ideal because the rigidity allows for relatively fool-proof, unattended installation. While a lot of people slide their feet when they walk, it’s really hard to kick up a graphic off of a hard surface,” says Eric Norby, product manager, FDC Graphic Films, Inc.
Material construction should be considered in terms of matching like products—i.e. the base material type should match the overlaminate. “Monomeric substrate with monomeric overlaminate, polymeric with polymeric, cast with cast, and so on. Or the overlaminate film must be of higher grade, like a monomeric substrate with polymeric overlaminate or a polymeric base with cast overlaminate—since homogenous shrinkage is acceptable or cannot be perceived,” notes Massimo Vettorazzo, owner, Flexa S.R.L, exclusively distributed by Cutworx USA in North America.
While Tony Caruso, VP of sales, Advanced Greig Laminators, Inc. (AGL), agrees that primary features in an overlaminate are scruff resistance and anti-slip certification, understanding the overall intended use and application are critical. “There is no one-size-fitsall product. Indoor versus outdoor; high versus low traffic; the type of surface; short, medium, or long term; these are just a few questions that will determine what features are required.”
“It’s important to think about the floor graphic in the environment, whether it’s at a stop-and-stand point or in a walking aisle, if it will
see heavy or light traffic, carpet or smooth flooring, indoor or outdoor. These then factor into whether the solution requires features like higher durability, a thicker laminate, or a more aggressive adhesive,” adds Matt Edwards, product manager for digital print media, General Formulations.
Hot or Cold Laminate
Hot or cold lamination to the base coat is required.
Edwards explains the process. “Both methods create a bond between the base layer and the laminate, where the cold laminate is doing so with a pressure-sensitive adhesive and the hot laminate uses a plastic melt layer. Cold laminate is more forgiving in terms of compatibility with the base layer, and the equipment is easier to use.”
“Because of cost and print engines that create the graphics, the majority of print providers have shifted their laminating equipment to either a cold-only process or utilize heat assist from their laminators,” adds Crosby.
Which method to use depends on the product at hand. “For example, a PVC film is very resistant to outdoor environments and can be applied cold, but ideally, it can be slightly heated—less than 40°C—to avoid the silvering effect and improve the lamination. The temperature-pressure ratio is decisive,” shares Vettorazzo.
“Cold lamination offers a larger variety of material types and thicknesses, allowing for a greater range of floor graphic applications,” notes Caruso.
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4) Distributed by Cutworx USA in North America, Flexa Easy Lite is a hot laminator with an upper roller that can reach up to 60°C. It features titanium coated blades.
Cold lamination is also beneficial because it works with all types of ink sets, according to Ramos.
Heiob almost always recommends cold lamination “because it will reduce the chance of overstretching, which causes the overlaminate to want to pull back after being applied to the print media.”
“Excessive heat during lamination can lead to flattening, deformation, and curling of the final product. Using an ultra-smooth film liner in the construction of a laminate helps to yield flawless results using the cold laminate method,” shares Velez.
Negated Traction
Running an overlaminate through a laminator may raise concern that the anti-slip properties of the media could be negated.
Leblanc says operators should take into account tension and/ or heat assist on their laminating equipment. “A good rule of thumb is to always use the least amount of tension, pressure, speed, and heat—if applicable—to create good output. Too much tension paired with too much heat assist can stretch the lamination, which could have an effect on the anti-slip properties as well as the overall lifespan of the graphic.”
“Depending on the media, too much applied tension can create excess stress, causing it to contract. As it contracts, the overlaminate could buckle and become a potential hazard,” explains Caruso. A laminator that provides process control feedback helps avoid this.
Since the non-slip properties come from the texture of the film or a coated grit surface, Richardson believes “a quality laminate or well anchored grit will not be negated by the pressure of a laminator.”
Smith seconds that a “good quality laminate should not be damaged by a laminator.”
“In order to change the film properties you would need to use an excessive amount of heat in the process. It is always recommended to use as little heat assist as possible to avoid shrinkage or tension on the finished graphic,” adds Edwards.
Heavy Responsibility
The overlaminate in a two-step floor graphic system is held accountable for safety, visibility, and durability. Considering the heavy load it bears, it is important the right media is chosen so it excels in its intended environment. D
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any of us expected 2023 to be a breakout year compared to the ones prior. Annually we partner with IT Strategies to review the last 12 months and forecast into the next five years. Marco Boer, VP, IT Strategies, shares in his report that wide format graphics inkjet revenues will grow five percent annually between 2020 and 2028. However, even at that
by Melissa Donovan
growth rate, vendor revenues aren’t expected to return to 2019 revenues until 2028.
While the predicted growth is a bright spot, there areas of concern, specifically market maturity, consolidation, and higher productivity equipment. These influence where the graphic arts market goes next. To get a greater idea of this, we connected with
key manufacturers servicing the industry for their opinions, and compiled it into this year’s state of the industry report.
Great Expectations
Did we set lofty goals for 2023? Perhaps. The first part of the year seems to have been an Below) Art City Wraps of Oshkosh, WI won the 2023 Application of the Year for this semi-trailer wrap using Avery Dennison media.
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interesting mix of achievements and setbacks depending on who you speak with. Of course there is hope for the second half of 2023.
Positivity abounds, for example in sourcing substrates. “The industry is in a better position in terms of film supply versus this time last year. 2023 got off to a slow start but this was due to a mixture of normal seasonality and stock work down. There will be growth in the back half of the year, as raw material availability and stocking levels stabilize,” explains Alex Fox, product manager - graphics digital and signage materials group, Avery Dennison Graphics Solutions.
“2023 met or exceeded expectations in many ways. Print businesses ramped up production capacity and sought new ways to scale, integrate, and automate processes to improve efficiency and profitability,” shares Dr. Jonathan Rogers, global marketing and communications, Onyx Graphics, Inc.
Jodi Sawyer, strategic business unit manager - retail, FLEXcon Company, Inc., says many industries project positive single digit overall growth in 2023. She cites the National Retail Federation forecasting retail spending to increase by four to six percent; out-of-home advertising is estimated to increase by
3.4 percent according to Magna; and pharmaceutical, automotive, and electronics industries are also projecting positive growth for 2023. “With seasonal promotions, travel, and entertainment/ events increasing, we expect to see a positive impact on growth in the second half,” adds Sawyer.
“2023 definitely met and exceeded expectations especially due to the return of trade shows. It’s only been a year since trade events have returned and when you think of these shows and the increased attendance, there is a need for more and different types of signage. Trade events are a great forum for
idea sharing, which translates into increased product sales,” suggest Edwin Ramos, director of sales and Aarona Tesch, product marketing manager, ACCO Brands.
X-Edge Products, Inc. experienced greater growth than it originally forecasted in the first half of the year. “With that 2023 has had its own unique challenges. From marketing a rapidly growing product line and also bringing on new distribution. We feel the second half will be stronger than the first because we have worked through these challenges,” notes Josh Martinez, account manager, X-Edge Products.
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“It's been a strong year in regards to finishing. Customers report difficulties hiring qualified labor and are investing in equipment and automation software to meet their production needs,” explains Keith Verkem, senior product manager – sales, product development, marketing, Colex Finishing, Inc.
Another player in the finishing segment, Martin Thornton, business segment manager, Zund America, Inc., attests that “our company experienced a tremendous first half of 2023, and the second half is looking just as strong. The growth, particularly in digitally printed packaging, continues unabated.”
ALLPRINTHEADS’ sales increased by 20 percent compared to last
year, despite concerns about a potential recession causing economic problems in 2023, shares Jaime Ghisays, CEO, ALLPRINTHEADS.
“This leaves us optimistic about the year’s second half and the potential for continued success. The printing industry is expected to generate nearly $193.5 billion in sales in 2023.”
“The demand has been higher than expected and that continues to grow as we enter the second half. Companies are in search of solutions that will improve their business and costs related to that,” says Brian Coombs, director, product planning, Canon U.S.A., Inc.
Vendors set the bar high for themselves. “There are a lot of new entries sprouting up in the printing and graphic arts worlds, adding a lot of competition in the market,” according Danny Jimenez, senior print media sales consultant, TVF.
“Printers are expressing that while business results are generally good, there is an uncertainty tied to concerns over the capital markets and broader economy. This combination of factors has caused greater caution toward capital expenditures,” notes Erik Norman, president, swissQprint America.
Shaun Holdom, marketing manager, high end, Fujifilm, agrees with customers/printers being more cautious with purchases, particularly “given the state of the world there are certainly some dynamics and challenges that are out of our control. The global issues on energy and potential recessions around the world, the increased cost of borrowing has meant all buyers are far more diligent on any purchases—especially equipment.”
“Someone jokingly told me back when I started in this industry 28 years ago that you need a sign whether you are going in or out of business. This is the closest to a recession-proof industry as I have seen. So looking forward I predict that the markets will be tentative for growth but the industry will find ways to keep growing via the many exciting new applications that are available to end users these days,” suggests Brian Phipps, president/GM, Mutoh America, Inc.
Despite uncertainty based on higher interest rates and a potential recession, Kevin Duffy, VP, sales and marketing, Vycom, says “display graphics will always be in demand and as a tool of commerce, will regularly need to be changed, ensuring a steady revenue stream for print service providers (PSPs).”
Static graphics are what Darius Augustine, GM and lead designer Alpina Manufacturing, LLC, refers to as a “soft sell”—easy on the eyes, noticed and absorbed, durable, and can be hung anywhere. Adversely, “electronic boards and displays are making big inroads, but the human brain is tired, overtaxed, and overwhelmed with electronic images.” Hence, why display graphics remain relevant.
Defining Moments
Technologies that defined the last six to 12 months range from textile printing innovation to smaller format UV flatbeds. Many are set to continue making buzz into 2024.
PSPs using flatbed printers are changing, embracing new markets and applications. “Opportunities are expanding within interior décor markets and the use of functional substrates, where the ability to replicate textures and deliver precise color matching are enabling printers to recreate wood, tile, and even shingles. Printing on wood, glass, and metals for various functional applications is also gaining ground,” shares Norman.
Similarly, textile printing is morphing as more efficient processes are discovered. “One influential trend is the increased use of direct disperse printing with inline fixation technology. It’s been used in Europe for years, but more U.S. companies are tapping into it and they need textiles that are compatible. These shops want to load the fabric, print it, and get to work on finishing,” explains Jimenez.
“Dye-sublimation has been an area of immense growth recently,
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1 ) AMI Graphics, Inc., based in Strafford, NH, won second place with its work for Now & There Inc. Artist Yenny Hernandez, part of Now & There, designed a colorful, gigantic display titled Ponle Vuelo A Tus Sueños/Let Your Dreams Take Flight for the Prudential Center in Boston, MA.
and we attribute that to the comeback after following an absence of trade shows,” notes Larry D’Amico, director of sales, Durst US.
A significant trend witnessed by Eyal Friedman, VP of product management, SA International, is direct to film technology. As it “is affordable, provides the ability to use a range of fabrics, the colors are vibrant, and there is an option to use white ink. Furthermore, direct to film printers are ideal for both long and short runs with minimum setup time.”
Michael Aldrich, product manager, FDC Graphic Films, Inc., supports direct to film becoming even more important. “This technology is very cost effective and is affecting a lot of the color heat transfer vinyl business, especially for short-run jobs in screenprint houses. This process also eliminates weeding out vinyl and layering multiple films to get a dimensional effect.”
Desktop flatbed printers present new opportunities. “Print shops have outsourced ADA/ braille signage in the past but UV printers make it simple for any print company to get in the game. ADA/braille is a requirement for many municipalities so having the capability to supply hundreds or even thousands of ADA-compliant braille signs to hotels, schools, government agencies, and businesses is a game changer if it can be done in house,” recommends Phipps.
Hybrid—flatbed and roll—devices also offer endless options. “Customers are looking for devices that can be flexible and offer multiple applications in a single device, so
the popularity of hybrid machines is becoming more evident. Having the ability to print both rigid and roll materials and offer a variety of applications—which are true revenue generators and can offer vertical market opportunities—is key,” explains Holdom.
“Flexible solutions at affordable prices and a bit slower speeds are preferred as well as special functions that add value are welcomed,” seconds Juan Kim, CEO, Valloy Incorporated.
Integration between software systems is a hot topic. “More companies—not just printers but vendors—are realizing their software is more powerful if it can be directly tied to the other systems that their customers use,” shares Andrew Oswood, wizard of workflow, Significans Automation.
“While workflow automation still means different things to different people, the idea of connectivity and integration across business tools and the advent of print business management solutions are technological trends that have gained and will continue to gain momentum in the print industry into 2024,” adds Rogers.
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Finishing trends focus on automation and software that minimizes operator intervention. “This includes complete print/cut solutions for rigid media with the use of conveyor belts for offloading and loading material inline between printers and cutters. On the roll media side its devices that load jumbo rolls into printers and then directly feed the cutter and stack the final product,” notes Verkem. digitaloutput.net August 2023 | Digital Output { 17 }
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“Automation is what it’s all about, with every manufacturer looking to get the best possible productivity from their investment in technology while, at the same time, minimizing the need for human intervention. Robots play a significant role in this, as ‘co-bots’
working alongside operators and as industrial, autonomous robotic systems capable of working unattended, non-stop, around the clock,” agrees Thornton.
The laser side of the finishing industry also feels the effects of
automation. “There is an increase in the use of overhead positioning cameras. Another trend is the replacement of old-fashioned print drivers with network-operated laser operation software, which is user friendly and allows for more operational control
• WEBSITE INFO#
Michael Aldrich, product manager, FDC Graphic Films, Inc. 188 fdcfilms.com
Jodi Sawyer, strategic business unit manager - retail, FLEXcon 189 flexcon.com
Micah Causey, VP business development, FloorSignage, LLC 190 floorsignage.com
Shaun Holdom, marketing manager, high end, Fujifilm 191 print-us.fujifilm.com
Michael Maxwell, VP of sales, General Formulations 192 generalformulations.com
regardless of the operating system,” explains David Stevens, technical development manager, Trotec Laser Inc.
Next Big Thing
Overwhelmingly vendors agree that we are headed toward an
INDUSTRY
Andrew Oswood, wizard of workflow, Significans Automation 197 significans.com
Erik Norman, president, swissQprint America 198 swissqprint.com
Carl Sommerstad, commercial director, Tekra, Inc. 199 tekra.com
David Stevens, technical development manager, Trotec Laser Inc. 200 troteclaser.com
Danny Jimenez, senior print media sales consultant, TVF 201 tvfinc.com
materials group 184 Avery Dennison, graphics.averydennison.com
Cassandra Yu, market segment development mgr. - architecture & retail 184 Avery Dennison, graphics.averydennison.com
Brian Coombs, director, product planning, Canon U.S.A., Inc. 185 usa.canon.com
Keith Verkem, sr. product mgr. – sales, product development, marketing 186 Colex, colex.com
Larry D’Amico, director of sales, Durst US 187 durstus.com
Amanda Smith, marketing and communication manager, Mactac 193 mactac.com
Brian Phipps, president/GM, Mutoh America, Inc. 194 mutoh.com
Dr. Jonathan Rogers, global marketing & communications, Onyx Graphics. 195 onyxgfx.com
Eyal Friedman, VP of product management, SA International 196 thinksai.com
Sean Davis, director of technology, Significans Automation 197 significans.com
Juan Kim, CEO, Valloy Incorporated 202 valloy.com
Kevin Duffy, VP, sales & marketing, Vycom 203 vycomplastics.com
Josh Martinez, account manager, X-Edge Products, Inc. 204 xedgetools.com
Martin Thornton, business segment manager, Zund America, Inc. 205 zund.com
2 INDUSTRY LEADER PARTICIPANT • COMPANY • WEBSITE INFO# Edwin Ramos, director of sales, ACCO Brands 180 accobrands.com Aarona Tesch, product marketing manager, ACCO Brands 180 accobrands.com David Graves, sales & marketing manager, Aleyant 181 aleyant.com Jaime Ghisays, CEO, ALLPRINTHEADS 182 allprintheads.com Darius Augustine, GM & lead designer, Alpina Manufacturing, LLC 183 fastchangeframes.com Alex Fox, product manager - graphics, digital & signage
INDUSTRY LEADER PARTICIPANT • COMPANY
LEADER PARTICIPANT • COMPANY • WEBSITE INFO#
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automated future, which makes for intelligent printing.
Reducing the level and/or need for manual operators drive this. “Many companies struggle with labor shortages and need automation. Part of this automation process includes allowing their customers to receive pricing instantly and to submit jobs online. Users are looking to automate many redundant proofing and prepress tasks,” notes David Graves, sales and marketing manager, Aleyant.
“Whether it’s to help with efficiencies as the workforce talent pool remains tight or in the form of software that’s become more user friendly, automated processes are getting more prolific and refined,” agrees Jimenez.
According to Coombs, “the adoption of new technologies will reduce reliance on resource-intensive processes, leading to improved productivity, significant cost savings, decreased material waste, and enhanced sustainability.”
And it isn’t just printing. “Automated handling, automation from printer to cutter and beyond, people are interested in how they can improve their operations with automation,” admits D’Amico.
Working in conjunction with automation is artificial intelligence (AI) and machine learning (ML). “Integrating AI and ML into
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2) The third place winner of this year’s Application of the Year awards, Turner Signs of Barnsley, U.K., created exterior wall graphics with a Mexican aesthetic using Drytac media. 3) The honorable mention winner is TPM Color Lab, recognized for its multi-faceted wall graphic for Elevation Church.
graphic design software is one of the most significant trends. This technology can automate repetitive tasks, such as formatting and resizing images, freeing designers to focus on more creative aspects of their work. Also, AI is incorporated into hardware, so printers become more intelligent in how they diagnose themselves and detect problems,” states Ghisays.
“Needless to say, AI will have more of an impact on the way we go about producing things as well, not only in terms of design/ content generation but also in machine and process control,” adds Thornton.
With it being such a hot-button topic, Stevens notes that six to 12 months from now the uses and regulations surrounding AI-generated content could look different.
Sean Davis, director of technology, Significans Automation, also believes ML will play a bigger role in the industry. “Both hardware and software solutions will be pushed to their extremes in process automation and quality control. Many manufacturing and software companies have been dabbling with AI for years, and this will continue.”
“We anticipate individuals and companies alike will monitor and
explore how to adopt AI technology to enhance the graphic arts. Augmented reality (AR) is a growing trend that companies will need to consider as the blend of digital and real-world graphics become more prevalent. For example, retailers are looking at ways to adopt AR to help customers navigate in-store more easily compared with wayfinding graphics,” shares Cassandra Yu, market segment development manager - architecture and retail, Avery Dennison Graphics Solutions.
Sawyer agrees that “AR and other technologies that support the needs of consumers to personalize
how they interact with brands to shop, work, and play will change the role of the graphic arts.”
Beyond automation, AI, and AR, Amanda Smith, marketing and communication manager, Mactac, stresses sustainability as a continuing topic of conversation. “The demand will lead to more investment in sustainable technologies. Next time you see graphics on walls and windows, you could be looking at a more environmentally friendly product, which a year or two ago was not the case.”
“There will be advancements in PET films that perform more like a
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true PVC product. Sustainability is in big demand,” seconds Aldrich.
It isn’t only the material itself that will be addressed. “The total footprint of the product, not just the end-of-life disposal, needs to be considered. As we continue to explore options, our focus has been on improving the raw material sources, components, processing, and handling throughout the entire supply chain so the product is produced as responsibly as possible,” suggests Michael Maxwell, VP of sales, General Formulations.
Despite the renewed interest in sustainable materials, Carl Sommerstad, commercial director, Tekra, LLC, believes the trend will only gain full traction when the media becomes “cost effective and we have not arrived at this point yet in the U.S.”
“Options for sustainable graphic products have been available for several years but it is also associated with higher costs for those wanting to do good, so many prospective users have continued to choose less-expensive PVC. Increasing pressure, more incentives, plus wider adaption of sustainable products in Europe is nurturing greater awareness and interest to businesses in North America,” explains Micah Causey, VP business development, FloorSignage, LLC.
Phipps says the future involves two “Ps”—packaging and personalization. “Packaging is a huge market. There is no better way than having luxurious-looking packaging to get the attention of the buyer. Whether it is your vehicle with a personalized wrap or a pen or award with
your name on it, there is no end in sight for the unique personalized product people want to buy.”
Ramos and Tesch agree packaging and customization are standouts to watch for. “There is continued interest in short-run, on demand printing for limited and customizable applications from traditional commercial print to increased folding carton and corrugated.”
17 ALL PRINTHEADS 22 allprintheads.com
18 Alpina Manufacturing, LLC 22 fastchangeframes.com
19 Alpina Manufacturing, LLC 22 bannergrip.com
1 ASLAN - A POLI-TAPE Group Company 11 aslanvinyls.com
2 Better Life Technology 8 bltllc.com/gfg
3 Colex Finishing, Inc. 15 colex.com
20 Delivery Signs 22 yardsignsresellers.com
21 DGS - Digital Graphic Systems Inc. 22 dgs-usa.com
4 Digital Dolphin Products 17 ddp.us
5 Drytac 17 drytac.com
6 FDC Graphic Films, Inc. 20 fdcfilms.com/3521
7 Fellers 27 fellers.com
8 FLEXcon Company, Inc. 19 www2.flexcon.com/do823
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The capabilities of printers—and the software that drives them— are further solidifying the introduction of new trends like printing multilayers for texture. “This is done using varnish ink, printing sandwich mode—CMYK-> White-> CMYK—for dual visibility, or for achieving an effect day and night,” explains Friedman.
To attract the attention of the passerby—but complement static print—Augustine also believes the ability to print textures is a future trend. “This is an innovation in the printing industry where a printer is capable of printing raised lines or microscopic 3D-type printed bumps such that as you pass the printed image, it changes in appearance in some manner to attract the person to look at the ad.”
At the Center of It Conversations on sustainability,
automation, and everything in between, but it’s important to remember at the heart of it is the PSP. This article includes images from 2023 Application of the Year winners. Congrats to Art City Wraps for winning first place— read more on page 7. For information on the rest of the honorees visit digitaloutput.net. D
9 ImagineThis 5 imaginetr.com
10 Jessup Mfg. Co. 13 jessupmfg.com
11 Marabu North America 25 marabu-northamerica.com
12 Mutoh America, Inc. 2 mutoh.com
22 Neenah Inc. 22 neenahpaper.com
13 Nekoosa 11 nekoosa.com
INFO# ADVERTISER PAGE WEBSITE
14 Newlife Magnetics, LLC 25 newlifemagnetics.com
Processing 9 panel.com 16 Signs365 28 signs365.com INFO# COMPANY PAGE 100 ACCO Brands 10 180 ACCO Brands 14 101 Advanced Greig Laminators, Inc. 10 181 Aleyant 14 182 ALL PRINTHEADS 14 183 Alpina Manufacturing, LLC 14 102 ASLAN Selbstklebefolien GmbH 10 220 Avery Dennison Graphics Solutions 7 103 Avery Dennison Graphics Solutions 10 184 Avery Dennison Graphics Solutions 14 185 Canon U.S.A., Inc. 14 186 Colex Finishing, Inc. 14 104 Cutworx USA 10 105 Drytac 10 187 Durst US 14 106 FDC Graphic Films, Inc. 10 188 FDC Graphic Films, Inc. 14 107 Flexa S.R.L. 10 189 FLEXcon 14 190 FloorSignage, LLC 14 191 Fujifilm 14 INFO# COMPANY PAGE 108 General Formulations 10 192 General Formulations 14 109 Graphic Finishing Partners, LLC 10 110 Jessup Manufacturing Co. 10 111 Mactac 10 193 Mactac 14 194 Mutoh America, Inc. 14 112 Nekoosa 10 195 Onyx Graphics, Inc. 14 221 Roland DGA Corporation 7 196 SA International 14 197 Significans Automation 14 113 Substance Incorporated 10 198 swissQprint America 14 199 Tekra, Inc. 14 200 Trotec Laser Inc. 14 201 TVF 14 202 Valloy Incorporated 14 203 Vycom 14 204 X-Edge Products, Inc. 14 205 Zund America, Inc. 14 digitaloutput.net August 2023 | Digital Output { 21 }
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hile wide format graphics output is profitable, there are related challenges, including market maturity, consolidation, and higher productivity equipment. First, market maturity—wide format is a replacement market. Secondly, consolidation and external competition drive the market to become a more professional managed business that depends on greater investment in automation and software. Finally, a shift to higher productivity equipment tends to have lower consumable costs.
This last point works in favor of more productive—i.e. faster drying—ink technologies, such as UV-curable and latex/eco-solvent ink chemistries. IT Strategies projects UV-curable wide format inkjet printers will be the fastest growing segment through 2028, while eco-solvent/latex remains the largest category in volume and revenue through the sheer scale of its install base. Overall, IT Strategies projects wide format graphics inkjet revenues will grow five percent
annually between 2020 and 2028, as illustrated in Chart A. However, at that growth rate vendor revenues won’t return to 2019 revenues until 2028.
The rest of the report breaks down the market by ink technology—aqueous, eco-solvent/latex, UV-curable, and soft signage dye-sublimation (dye-sub).
Aqueous Wide Format Inkjet
Aqueous wide format graphic printers— specifically those in the six- to 12-color range—struggled in 2022. Aqueous unit sales were down 20
by Marco Boer
percent from 2021/2022. The decline is a bit misleading as the high number in 2021 was a reflection of pent-up demand coming out of the COVID-19 pandemic.
$4.5 $4.0 $3.5 $3.0 $2.5 $2.0 $1.5 $1.0 $0.5 $0.0 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 Total WFG $4.2 $2.8 $3.1 $3.1 $3.3 $3.4 $3.6 $3.7 $3.9 $4.2 CHART A WIDE FORMAT GRAPHICS Total Inkjet Hardware & Ink Vendor Revenue $M, Worldwide 2020 to 2028 digitaloutput.net August 2023 | Digital Output { 23 }
A long-term challenge for aqueous wide format graphics printers is the continuing shift to CAD units for graphics usage, a market four to five times larger than aqueous wide format graphics. Four-color wide format CAD inkjet printers are capable of creating even photographic quality when using photobase inkjet coated papers—relegating the six- to
12-color wide format graphics printers for all but the highest output quality applications.
Demand for 24-inch printers spiked in 2021 in part because more graphics professionals were working from home. For as little as $1,000 they could buy a wide format graphics printer. The 36inch and over wide format graphics
printers were susceptible to substitution by 36-inch CAD printers.
The installed base is seeing a lot of retirements, mainly due to inactive printers during COVID-19 failing beyond economically viable repair. Effectively IT Strategies is projecting flat growth for the installed base of aqueous wide format printers.
One additional source of competition for aqueous wide format is from specialties like dye-sub and canvas prints on latex. Eco-solvent and latex are expected to continue to steal share from aqueous as they feature lower cost inks.
In Chart B, hardware and ink revenues are depicted as falling over 30 percent during COVID-19. Combine this with strong competition from aqueous CAD and eco-solvent/latex printers and IT Strategies expects vendor revenues for hardware and ink to remain flat through 2028, never recovering to 2019 levels. While no one likes flat revenues, it is an indication of market maturity. It also means there is less investment required in innovation.
Eco-Solvent/Latex
Designed for outdoor and indoor use, eco-solvent and latex segments are expected to continue to grow as applications expand beyond signage into décor. 2022 was a transition year in new product introductions effecting unit sales, enabling eco-solvent to pick up share with its much broader offerings.
Like the aqueous wide format segment, there is a lot of transition. There is a high rate of retirements of older machines and
new replacement sales have kept the installed base flat, with uptick expected as these products start to displace more screen/offset output.
Low-end latex printers sell for under $50,000; high-end latex printers sell for over $100,000. The high-end latex printers are used for décor printing, such as wallcoverings and furnishings. They account for a small part of the installed base, but because of their productivity they capture a far greater proportional share of revenues than eco-solvent or low-end latex printers. Productivity is key—high-end latex accounts for two percent of the installed base, but ten percent of vendor revenue.
Combined, eco-solvent and latex account for almost half of vendor revenue share of the wide format graphics print market, making it the largest revenue segment of the wide format print market—as seen in Chart C.
UV-Curable
UV-curable inks are instant dry, feature less maintenance between jobs, and enable productivity. In wide format graphics, UV-curable inkjet presses are productive and correspondingly offer the lowest cost of print—providing there is sufficient print volume. Initially offered in flatbed format to conform to conventional screen press formats, roll-to-roll (R2R) UV-curable printers now account for about one-third of all UV-curable wide format graphics printers sold.
Flatbed
The UV-curable market was hard hit by COVID-19, as demand for high-volume signage disappeared. There is a strong recovery in UV
$700 $600 $500 $400 $300 $200 $100 $0 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 36"+ $492 $274 $304 $304 $309 $296 $294 $289 $284 $280 24" $130 $112 $131 $123 $124 $120 $117 $110 $105 $101 CHART B $2,000 $1,500 $1,000 $500 $0 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 High-End Latex $203 $121 $133 $127 $137 $148 $162 $181 $203 $229 Low-End Latex $475 $290 $371 $336 $341 $348 $365 $398 $445 $501 Eco-Solvent $1,253 $948 $907 $976 $1,014 $1,022 $1,056 $1,102 $1,175 $1,258 CHART C ECO-SOLVENT AND LATEX INKJET HARDWARE & INK VENDOR REVENUE $M Worldwide 2020 to 2028 AQUEOUS INKJET HARDWARE & INK REVENUE $M Worldwide 2020 to 2028 August 2023 | Digital Output digitaloutput.net { 24 }
flatbed. IT Strategies projects this segment will be back to 2019 unit shipment levels in 2023/2024. It is the sheer number of competitors and productivity that makes UV-curable the strongest growing sector in wide format graphics.
Driving this growth is sub-$75,000 products on the low end. Those units are key to driving flatbed UVcurable unit growth, and account for over 40 percent of all low-end shipments. A use in the U.S. for these systems is lawn signage, the demand for which exploded during COVID-19 for graduations, fundraisers, and election campaigns.
The high-end flatbed unit shipments declined in 2022, due to lack of components required to ship those products. Additionally, the majority of systems today use LED curing lamps, which has reduced energy use/heat and extended the curing lamp life. Because these systems have a higher
acquisition cost, print providers tend to hold on to them longer than other wide format systems.
In comparison to aqueous and eco-solvent/latex technologies, UV-curable flatbed installations account for about eight percent of the installed base of wide format graphics printers. They are closest in productivity to replace screen print. This is why a six percent growth in installed base 2023 to 2028 is projected and will drive seven percent growth in hardware and ink revenue, see Chart D.
R2R
IT Strategies segments R2R between low end of under $150,000 and high end of over $150,000. More than 90 percent of low-end R2R printers are priced under $75,000, some as low as $16,000.
The young base of low-end, R2R printers drives installed base growth since there retirements.
#14 #11 $1,200 $1,000 $800 $600 $400 $200 $0 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 High-End Flatbed $573 $103 $122 $122 $138 $145 $158 $170 $182 $178 Low-End Flatbed $498 $318 $383 $451 $486 $536 $574 $611 $649 $690 CHART D UV-CURABLE FLATBED INKJET HARDWARE & INK VENDOR REVENUE $M Worldwide 2020 to 2028 digitaloutput.net August 2023 | Digital Output { 25 }
This is unlike the more mature high-end R2R installed base, which is seeing higher rates of product retirements.
Because of the relatively young installed base, the compound growth of the installed base, and rising average monthly print volumes, hardware and ink revenue growth are expected to be strong through
2028 in both the low and high end of the R2R UV-curable market segment, which is shown in Chart E.
Soft Signage Dye-Sub
Wide format dye-sub printers are used for many applications with a polyester base, including sportswear apparel, fashion apparel, transfer to hard polyester surfaces, and soft signage.
The vast majority of low-end dye-sub soft signage printers sell for under $15,000. They are easy to buy, and provided there is a capable operator, offer among the highest margins of wide format output. The resurgence of trade shows helps fuel the use of existing installed soft signage printers, but this has not translated into growth of new dye-sub soft signage printer sales.
Aside from aqueous wide format printing, this is the only sector where unit volumes declined from 2021 to 2022.
The installed base of soft signage printers is recovering well from its 2020 COVID-19 decline. Over time IT Strategies expects the installed base to be relatively stable. The single biggest barrier to faster growth in soft signage is the high cost of material and skill required.
The rising productivity of hardware drives up average monthly print volumes, resulting in higher consumable revenues per printer.
As seen in Chart E, this gets hardware and ink vendor revenues back up to 2019 levels sometime after the forecast period.
Editor’s Note
Overall the wide format graphics market inkjet revenues are projected to grow five percent annually between 2020 and 2028. What’s interesting is the break out between ink technologies.
According to IT Strategies, relatively low-priced aqueous and eco-solvent/latex printers continue to dominate unit sales of wide format printers. In Chart G, you can see how they are capturing a combined share of the market at about 80 percent of units sold. D
About the Author
Marco Boer, VP, IT Strategies has more than 25 years of experience in advising and guiding senior executives of Fortune 1000 and smaller companies to successful business solutions in emerging digital printing markets, Boer has a deep understanding of inkjet printing technology and its applications.
$350 $300 $250 $200 $150 $100 $50 $0 70,000 60,000 50,000 40,000 30,000 20,000 10,000 0 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 High-End Soft Signage Dye-Sub $151 $51 $50 $67 $69 $75 $79 $83 $87 $91 Low-End Soft Signage Dye-Sub $197 $143 $130 $170 $176 $195 $207 $216 $226 $235 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 Dye-Sub 10,060 8,313 7,910 6,866 7,003 7,704 8,089 8,331 8,581 8,839 UV-Curable 5,480 4,323 5,523 6,115 6,295 6,600 6,720 6,815 6,910 7,008 Eco-Solvent/Latex 28,157 21,970 25,331 25,060 26,335 27,332 28,217 29,146 30,120 31,142 Aqueous 26,134 24,498 30,136 23,950 23,711 23,473 23,239 23,006 22,776 22,548 CHART F CHART G $400 $350 $300 $250 $200 $150 $100 $50 $0 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 High-End R2R $83 $16 $50 $93 $117 $138 $158 $162 $165 $168 Low-End R2R $180 $133 $170 $184 $198 $210 $218 $223 $224 $228 CHART E SOFT SIGNAGE DYE-SUB INKJET HARDWARE & INK VENDOR REVENUE $M Worldwide 2020 to 2028 TOTAL MARKET INKJET UNIT FORECAST BY INK TYPE Worldwide 2020 to 2028 UV-CURABLE R2R INKJET HARDWARE & INK VENDOR REVENUE $M Worldwide 2020 to 2028 August 2023 | Digital Output digitaloutput.net { 26 }
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