Digital Output Jul 23

JULY 2023

pg. 13

Movie Theater Spotlight | pg. 6 DIGITALOUTPUT.NET VOL XXIX, NO. 7 • $6.95 USA

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Fabric from Post-Consumer Waste | pg. 22 Cutting Magnets | pg. 25 6/23/23 10:03 PM

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features ON THE COVER: SPGPrints offers high-speed printing devices for textiles. See page 13.

8 } Magnetic Momentum From POP to Vehicle Messaging Where to use different material options.

by Cassandra Balentine

Departments

13 } Faster than Fast

Marketplace ................................................................. { 5

High-Speed, Dye-Sub Printing A need for speed in textile printing.

Application Spotlight ................................................. { 6

22 } Commitment to the Environment

Editor’s Input ................................................................ { 4

Target Chart .................................................................{ 18

Plus Marketplace Spotlight ................................................ { 5 Showcase Advertisers............................................... { 20 Advertiser’s Index ........................................................{ 21 Companies Mentioned ..............................................{ 21

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by Digital Output Staff

Fabric Made Up of Recycled Components Supporting the use of post-consumer waste products is good practice.

by Melissa Donovan

25 } Finishing Magnetic Material Consider Your Finishing Tools How to meet challenges head on.

by Digital Output Staff

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C A P T U R E

C R E AT I O N

O U TPUT

VOLUME XXIX, NO. 7 DIGITALOUTPUT.NET

FINIS HING

ISSN: 1083-5121

EDITOR IN CHIEF

Thomas Tetreault ttetreault@rockportpubs.com

Fabric and Magnets Entering the Summer months means our annual July issue with a focus on two very specific print mediums— textiles and magnets. They couldn’t be more different in terms of surface nor how they are optimized for digital inkjet printing, however they are frequently used across the graphic arts.

They couldn’t be more different in terms of surface nor how they are optimized for digital inkjet printing, however they are frequently used across the graphic arts.

Our cover story, Faster Than Fast, looks at high-speed dye-sublimation printing, specifically for textiles. Vendors in this space helped us define “high speed” and furthermore identify the prime candidate for the technology. A quick preview—those in the home decoration, events, and even apparel markets are poised to benefit from digital printing.

Also in the textile-based realm, feature on fabrics made up of recycled components like post-consumer waste from plastic bottles. The article addresses the advantages associated with using this specific media and more importantly how to determine if it is indeed worthy of its feature set. Read more in Commitment to the Environment. We also include a spotlight on a recent fabric-based job for a movie theater release—it illustrates just how flexible digitally printed textiles are.

Moving to magnets, Magnetic Momentum focuses on the ABCs—a primer if you will—of the various options out there from magnetic-receptive materials to magnetic strip. In addition, learn about cutting tools for magnets in Finishing Magnetic Material.

Enjoy your Summer, the busy Fall trade show season will be here before you know it!

Best regards, Melissa Donovan, editor mdonovan@rockportpubs.com

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EDITOR Melissa Donovan mdonovan@rockportpubs.com ASSOCIATE EDITOR Cassandra Balentine cbalentine@rockportpubs.com WEB EDITOR Melissa Mueller ART DIRECTOR Sarah M. White swhite@rockportpubs.com CONTRIBUTORS Olivia Cahoon, Tim Greene, Mark Hanley, Melinda Tetreault, Amber Watson ADVERTISING SALES PUBLISHER Thomas Tetreault NATIONAL ACCOUNT EXECUTIVES Nicole Pizzi-Cerundolo npcerundolo@rockportpubs.com 978-921-7850, Ext. 160 Amanda Doyon adoyon@rockportpubs.com 978-921-7850, Ext. 170 Subscribe online at digitaloutput.net

CORPORATE & PUBLISHING OFFICE 100 Cummings Center, STE 321E Beverly, Massachusetts 01915 ROCKPORT CUSTOM PUBLISHING, LLC CHAIRMAN Jeffrey Jensen PRESIDENT & CEO Thomas Tetreault Digital Output is published monthly by Rockport Custom Publishing LLC. ©Rockport Custom Publishing, LLC 2023. Reproduction by any means of the whole or part of Digital Output without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply our endorsement.

Vendors: We welcome your product news. Include prices, slides, photos, and digital files with your press release. Please forward product samples and media kits to Reviews Editor, Digital Output, 100 Cummings Center, STE 321E Beverly, MA 01915. We cannot be responsible for unsolicited product samples.

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POSTMASTER

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Periodical Class postage rates paid at Beverly, Massachusetts and additional mailing offices.

CHANGE OF ADDRESS NOTICE

Six to eight weeks prior to moving, please clip the mailing label from the most recent issue and send it along with your new address (including zip code) to: Digital Output magazine, change of address notice, 100 Cummings Center, STE 321E, Beverly, MA 01915. Attention: Circulation Department.

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Canon Extends Arizona Flatbed Printer Family Canon U.S.A. Inc. launches six new models in the Arizona 1300 flatbed printer series, the 1340/1360/1380 GTF and 1340/1360/1380 XTF, featuring FLOW technology, an innovative zone-free vacuum system that makes media handling easy.

Extending the comprehensive Arizona flatbed printer family, the Arizona 1300 series with FLOW technology serves the growing mid-volume segment,

ALLPRINTHEADS

SUPPLY55, INC.

enabling large format graphics printers and other print service providers to offer their customers an extensive range of applications for retail, interior décor, packaging, and industrial markets. Designed for productivity, the new printers enable users to produce versatile, accurate, and highly efficient multi-board and double-sided printing. The Arizona 1300 GTF joins the existing Arizona 1300 GT series while the Arizona XTF series replaces the current #200

Arizona 1300 XT series.

EFI Advances Display Graphics EFI makes the highly versatile, super high-speed, high-quality breakthrough capabilities of its Nozomi

Rely on Industry Experience

Finishing Simplified

Allprintheads is your one-stop source for your printheads, spares, consumables, and digital printing equipment. With more than 23 years of industry experience, you can rely on the company to provide the best advice for your printing needs. Allprintheads specializes in all types of printheads and spares for most digital printing systems. To learn more visit the website allprintheads.com, call 800-616-0584, or email sales@allprintheads.com INFO# 204

Engineered and manufactured in Europe, the KalaXY Cutter/Trimmer reduces labor and increases profits by eliminating the time consuming task of manually cutting printed digital images. The line of automatic XY cutters are the ideal solution for processing a wide range of media including wallpaper, paper, direct to film, canvas, laminated/encapsulated films, banner material, polycarbonate, and other non-woven roll goods. Increase your output while reducing operation costs with KalaXY Cutters. For more information visit supply55.com, call 734-668-0755, or email sales@supply55.com. INFO# 205

NEWLIFE MAGNETICS, LLC

ULTRAFLEX SYSTEMS, INC.

single-pass UV LED printing technology available to a greater number of sign and display businesses with the new modular and scalable EFI Nozomi 14000 SD printer. Available later this year, the basemodel, four-color, 1.4-meter wide EFI Nozomi 14000 SD prints paper, synthetic media, and board at speeds of up to 30 linear meters per minute. At that speed, customers can produce up to 740 1.4x2.4#201

meter sheets per hour.

World Premiere for Vanguard’s VK3220T-HS

Your Magnetic Solution

Take a Plunge, Make a Big Splash

Vanguard Europe unveils a next-generation UV flat-

Newlife Magnetics is the world’s largest manufacturer of flexible magnetic materials. Our company’s focus on science and engineering has led to our success in leading the magnet industry through research and development of exciting new products that solve customer problems, increase efficiency, and improve our customers’ lives without harming our environment. We offer a variety of products including Platinum magnetic-receptive, printable magnet media up to 60 inches wide, Cling King micro-suction films, and new pre-magnetized HP Indigo sheets. To learn more visit newlifemagnetics.com. INFO# 206

AquaFlex is a digitally-printable waterproof substrate designed to brand and advertise in pools, ponds, water features, and aquascapes. It's perfect for anyone looking to make a big impact with their marketing in new and innovative ways! AquaFlex is easy to install and position by hand or with a pool brush without draining water and is engineered to lay flat and remain in place without tape or adhesive. Plus, the material's blue backside is made from recycled industrial pool liner and made in the U.S. To request a printed sample of this unique substrate, visit ultraflexx.com. INFO# 207

bed printer, the VK3220T-HS. A 3.2x2-meter flatbed, the VK3220T-HS becomes part of Vanguard Europe’s growing portfolio of printers serving all customers in markets covering the industrial flatbed and roll-toroll printer spectrum with high-performance needs.

Using up to three rows of the four picoliter drop size Kyocera printheads at up to 1,800 dpi print resolution, the Vanguard VK3220T-HS runs at up to 360 square meters an hour.

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Grab Your Popcorn Major Movie Promoted with Digital Print

by Melissa Donovan

T

he return to movie theaters means an influx of promotional graphics for upcoming releases. The goal is for them to be immersive, exciting viewers for the next big cinematic experience. They range from pressure-sensitive floor graphics to traditional corrugated standees. Textiles are another option. Soft signage is an effective component in marketing campaigns because of its durability, visual aesthetic, and vibrant colors.

signage contractor covers events and exhibitions, property and construction, sport, entertainment, and retail industries across the U.K.

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It was recently tasked with creating graphics for Vue Cinema in Westfield, Shepherd’s Bush, London, which was looking to promote the upcoming The Super Mario Bros. Movie.

It’s-A Me, Mario

It wasn’t the first time Hollywood Monster worked with Vue Cinema. According to Noel Tilley, senior project Hollywood Monster, based out of Tyseley, Birmingham, manager, Hollywood Monster, “due to the longstanding U.K., is no stranger to completing signage for movie relationship with the theaters. The comclient, they underpany was established stand we have the cain 2009 when two Going forward this installation site will pability and skill set family businesses to undertake such an merged. Today it be changed quarterly, which is why the important project.” works out of a 3,530 track system is a great option for this square meter facility This was no ordinary with a team of over kind of project. job. Vue Cinema 40 signage and print — Noel Tilley, senior project manager, Hollywood Monster recently decided to experts. The wide utilize a specific area format printing and

1 & 2) Hollywood Monster printed and installed graphics for the recent The Super Mario Bros. Movie at Vue Cinema in London.

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of its theater to promote highly anticipated coming attractions.

The goal was to outfit the space with bright, impactful, actionpacked graphics—changing them out each quarter.

Print and Install

Hollywood Monster surveyed the intended area in December 2022.

The project was installed in April 2023. “We had time to arrange the install, but waited for approved artwork, which then was printed and installed in a short time scale,” explains Tilley.

Approved artwork included graphics for a mix of applications—one floor graphic, a wrapped archway, and one ceiling and three wall displays made up of fabric.

All of the media was printed on EFI VUTEk printers, specifically dye-sublimation for the fabric and UV for the floor graphics and archways. The finishing was completed with its fleet of Zünd cutters.

UTACK Multi-Surface Textile from CMYUK was used for the floor and a laminated permanent vinyl for the archway. UFabrik Soft Display Textile was the media of choice for the walls and ceiling.

UTACK Multi-Surface Textile is a unique removable, adhesive-coated textile designed for indoor/outdoor wall and floor graphics, with a lifespan of up to three months.

Suitable for carpet, wood, tiles, and concrete surfaces, this antislip vinyl has R12 rating, with B1 and M1 fire certifications.

UFabrik Soft Display Textile is suitable for both long- and short-term digitaloutput.net

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graphics. A soft crease-free display textile with a high knit density that accounts for over 80 percent opacity, it is designed for tension frame systems, banners, tablecloths, and backdrops. Compatible with dye-sub direct or transfer processes, it has an ideal white point, superb stretch, and recovery as well as punchy color reproduction.

It is fire rated EN13501-1, B1 and NFPA 701 certified.

“The UFabrik range of textiles covers about 95 percent of all wide and superwide applications. It’s high performing with excellent color reproduction and comes at an excellent price point. Products within the range include materials made from recycled PET plastic waste that have caught the attention of some of the world’s biggest brands that we service,” says Simon McKenzie, CEO, Hollywood Monster.

“Our client was delighted with the immersive graphics. They packed a powerful visual punch, elevating the ambient experience and enjoyment of the cinema-going public,” adds McKenzie.

The graphics were removed in May 2023. As of press time Vue Cinema and Hollywood Monster were consulting on the next movie premiere to promote in the space.

Settle In

Movie theaters are an excellent environment to create signage for—as new films are constantly introduced and promoted months in advance, graphics are never short on supply. Digitally printed graphics offer ease of install and removal while providing a highquality look and feel. D See page 21 for more info.

Graphics for The Super Mario Bros.

Movie theatrical release were printed and installed over two nights with a team of four installers. A track system was utilized for the fabric wall and ceiling graphics.

According to Tilley, “the track is mechanically fixed to the wall perimeter and around any switches/ sockets. The fabric is rolled out and pushed into the track using a crescent shaped hand tool and any excess fabric is then carefully cut off using a scalpel.”

Use of the track—and the fabric placed in it—was a strategic decision. “Going forward this installation site will be changed quarterly, which is why the track system is a great option for this kind of project,” notes Tilley.

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by Cassandra Balentine

agnets are a versatile medium for graphics and signage. From promotional use on refrigerators and vehicles to point of purchase (POP) and signage opportunities that are easy to install and remove in retail environments. { 8 } July 2023 | Digital Output

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Additionally, the media is available in magnetic and magnetic-receptive options, in a range of widths and thicknesses, and compatible with many print processes. Jack Nellessen, president, New Force Magnetics Co., breaks down the different magnetic options—printable

magnetic sheeting is for printing, magneticreceptive sheeting for attaching to a magnetic surface, and magnetic strip with adhesive for the backs of calendars or shelf marking. In this

Above) Sheet converting equipment at Adams’ Elmhurst, IL location.

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article we go through the advantages, limitations, durability, and recyclability of each solution.

Printable Magnetic Sheeting

One type of magnet common for wide format printing applications is printable magnetic sheeting.

This is used for a applications like vehicle graphics, signage, promotional labels, industrial tags, and POP and retail displays.

Magnet applications are often a one-part application with no magnetic base required, as long as there is iron in the surface.

One reason for the popularity of this media is the simple fact that it is the only suitable option for some applications—like refrigerator and vehicle magnets, says Lydia Amburn, operations manager, Newlife Magnetics LLC.

Standard magnetic solutions may also enable a lower cost of doing business in the short term. “End users with non-repetitive business would benefit from traditional magnetic,” comments Brian Ebenger, VP, business development, Xcel Products, Inc. Ease of installation is another major selling point for magnetic signage options. “Magnetic sheeting is simple to work with so no professional installation is needed,” shares Ebenger.

“It’s a simpler system if you already have a magnet-receptive surface. You only need the one piece of magnetic media and it’s easy to install,” adds Alice Martin, director of marketing, Adams Magnetic Products Co. digitaloutput.net

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The main limitation to magnetic sheeting material is width. Magnetic media is typically found in 48-inch widths or less, points out Ebenger. Comparatively, he says the industry standard for pressure-sensitive vinyl is 54 inches and banner medias are available as wide as 196 inches.

There are a range of compatible printing systems for magnetic sheeting, including digital inkjet—solvent, eco-solvent, and UV-curable, as well as flexography and screen. “Other options are available but may require non-magnetized products during printing based on printer technology. If non-magnetized material is required, a magnetizer is needed post print,” explains Ebenger.

In terms of durability, the life expectancy of printed magnetic sheeting is determined by a number of factors, but Ebenger notes that indoor applications can typically last a long time while outdoor applications will last about a year.

#1

Printed magnetic sheeting can be used indoors or outdoors, but Nellessen says there are some heat and cold limitations to consider.

The materials can easily be used for several years depending on the exposure to sun, adds Nellessen. Indoor use could be up to ten years.

When it comes to finishing, magnetic sheets are fairly straightforward—die cut, routed, even cut by hand are all options according to Ebenger.

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inches wide. It can be recycled with ink. “A durable printable coating is applied directly to our magnet sheet, eliminating the need for a laminated print surface. This makes it completely recyclable. Send it back to us and we’ll use it to make more GreenMAG.”

Magnetic Sheeting Options

Adams offers printable flexible magnet sheet available in 24-, 40-, 48-, 50-, and 60-inch widths, and is available in .015-; .020-; .030-, .045-, .060inch thicknesses.

1 “With proper care and maintenance, the magnet should last for years. Environment and ink durability will factor into overall durability,” adds Martin.

Ebenger recommends testing the material on the printer and application to ensure the material is compatible. “Magnetic material is typically heavier than other wide format products so just be aware for print and transportation purposes. Additionally, a clean surface is critical for the success of the application.”

1) Strip converting equipment at Adams’ Carlsbad, CA location.

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Sustainability, including recyclability, is always a consideration. Depending on the specific materials, recyclability of magnetic sheeting is possible—even when inked, but usually the product must be returned to the manufacturer, shares Amburn.

Ebenger says Xcel Products’ domestically made material can be recycled and the company has set up several recycling programs.

Martin cautions that magnetic media is not always recyclable, but Adams’ GreenMAG is a printable recyclable magnet up to 30

Magnum Magnetics Corporation provides several different versions of its magnetic sheets from DigiMag Vinyl—a direct printable media for solvent, eco-solvent, latex, and UV inkjet; to MuscleMag, which is a high-energy, thin printable magnet for digital and wide format inkjet presses.

Master Magnetics, Inc. offers PrintMagnetVinyl, which allows printing to white, black, blue, gold, green, orange, red, or yellow magnetic sheet using solvent, eco-solvent, UV, or latex ink. Rolls are available in ten to 50 feet long, 24 inches wide, and 20- or 30-mil thick.

New Force magnetic sheeting widths are available up to 60 inches but the most requested sizes are still between 24.375 and

48 inches due to the popularity of the more affordable small width printers, says Nellessen.

Newlife Magnetics manufactures flexible magnetic materials. “We can make our EM series magnet 60 inches wide. We strive to make products wider, thinner, lighter, and stronger,” shares Amburn.

Its magnetic sheeting options are available in 60-inch widths and thicknesses of .007 to .084 inches, depending on the SKU. Xcel Products offers its ACTION Magnet, which is domestically produced and designed to provide superior consistency with various options and minimal lead times.

“Additionally, we have several options including standard energy, high energy, and PVC free,” notes Ebenger. It provides 15-, 20-, and 30-mil thickness as standard products with an option for 60mil. Standard widths are 24.375, 40, and 48 inches, while its standard lengths are 50 and 100 feet.

“We have the capabilities to sheet to any size along with custom rolls to help support the needs of the industry,” shares Ebenger.

Magnetic Receptive

Magnetic-receptive media is a unique system with a magnetic base and magnetic-receptive product that sticks to it. Both magnetic sheeting and magnetic-receptive systems have a place and there is some application overlap.

Popular graphics printed for magnetic-receptive systems include small and large displays, menu boards, control charts, POP, educational and museum displays, picture frames, and wallcoverings.

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“Any surface that someone wishes to change out after initial covering” is a fit, recommends Nellessen.

Martin points out that these systems allow for displays to be quickly updated with no tools and minimal training.

“This material is used for ease of installation and quick change out for promotional and short-term events,” agrees Ebenger.

Amburn points out that magneticreceptive prints are lighter and less costly to ship compared to the standard magnetic offerings. Reusability is another advantage.

In terms of limitations, the biggest is that it requires a magnetic base. “Some challenges include a high initial cost to install the magnetic base along with magnetic receptive not being recyclable,” says Ebenger.

Amburn also finds consumer education for magnetic-receptive applications to be a barrier.

Magnetic-receptive materials are optimized for all common ink sets, including solvent, ecosolvent, and latex inks; conventional offset, flexography, lithography, and screen printing; and HP ElectroInk.

In terms of durability, Ebenger says magnetic-receptive applications can last for years based on the environment. “However, most are short term so it is typically not a concern.”

For outdoor use, Amburn notes that UV exposure is the primary factor for the degradation of all media types. “For long-term applications outdoors our PET options allow for years of continued durability and will not yellow or brown like PVC. In addition, our PET options are PVC free. There is little to affect the longevity of printable magnets indoors,” she continues.

Nellessen estimates longevity from three to ten years for indoor use.

In terms of recyclability, Ebenger says magnetic receptive is not recyclable—with or without ink.

Nellessen says it depends on the laminate, but it is usually not considered recyclable.

Newlife Magnetics is working on a process with Mid America Paper for recycling retired magneticreceptive graphics. “We will make further information available soon. For our FF series (540) we incorporate 32.4 percent postconsumer plastics in the binder.”

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Magnetic-Receptive Options Adams MAGbond Magnetic Receptive Sheets are available ten- or 12-mil thick, and come in 50-, 54-, and 60-inch widths with a PET surface for printing. MAGbond sheets are made by coating high-quality films with micro-iron particles and are engineered to be ultra-low profile for a seamless appearance of a single layer, photographic, or fine art quality print.

Magnum Magnetics has three different magnetic-receptive media lines. EnGage is a thin, printable magnetic-receptive media for wide format printers. RubberSteel is a lightweight rubberbased magnetic-receptive media available with multiple laminates.

PaperSteel is a magnetic-receptive sheet with a gloss white paper surface on one or both sides.

Master Magnetics’ FlexIRON magnetic-receptive sheeting is made with a high concentration of iron so it attracts all types of magnets.

It is part of the company’s Magnetic Graphics System, which is a three-layered system designed for graphics display.

New Force offers an adhesivebacked magnetic sheet that is adhered to a wall or other backer board. A changeable sign is then printed on a magnetic-receptive graphic, which is attached to the magnet. Its magnetic-receptive

companies mentioned

INFO# COMPANY 187 Adams Magnetic Products Co.

sheets are available in 50- and 60-inch wide format rolls.

Newlife Magnetics makes magnetic-receptive options ranging from HP Indigo sheets to 60-inch wide format options, in thicknesses from seven- to 12-mil—20 mils with PSA—and can make thicker by special order.

Xcel Products offers several different versions of magnetic-receptive material. “Our standard 13-mil material is available in 54-, 60-, and 74-inch widths. The company also offers an 18-mil, double-sided and latex version in 15-mil. Both standard roll widths are 60 inches,” shares Ebenger.

In addition, Xcel Products offers the SOLIX frame system, which is a framed magnetic base. Ebenger says these are gaining popularity in restaurants, museums, and trade show booths.

Flexible Magnetic Strip

Flexible magnetic strips are also utilized in the wide format print industry. Most applications for magnet strips do not overlap with that of sheet magnet or magnetreceptive products. The material is generally not printable/printed to.

Magnetic strips are used to hold something on a metal surface, like notepads, labels, and craft items, confirms Nellessen.

See page 21 for more info.

WEBSITE adamsmagnetic.com

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Magnum Magnetics Corporation

magnummagnetics.com

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Master Magnetics, Inc.

magnetsource.com

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New Force Magnetics Co.

newforcemagnetics.com

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Newlife Magnetics LLC

newlifemagnetics.com

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Xcel Products, Inc.

xcelproducts.com

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“Magnet strip has a wide array of uses and can be used to apply many non-magnet or magneticreceptive media to a metal or magnet base (such as A/B applications),” suggests Amburn.

“Magnetic strips are typically used to support rigid boards rather than flexible products like magnetic and magnetic receptive,” explains Ebenger. “This is ideal for an end user that would prefer a rigid display or freestanding display.”

Martin agrees, adding that a flexible magnet strip can be used around the perimeter of signs printed on several choices of material, so printers can work with materials they are comfortable with, and still make them magnetic by applying the magnet strip.

Limitations associated with magnetic strip media include the lack of options, says Ebenger. This is in addition to the competition of traditional tapes and Velcro.

Metal is required for the strips to adhere, which is a disadvantage for some applications.

Martin adds that careful consideration should be used when selecting an adhesive. “You need to be sure it is compatible with the surface you plan to apply it to.”

“The manual labor to apply the strip has been the limiting factor in using the product, but we have solutions,” adds Amburn.

“Magnetic strips are specialty driven but are compatible with most graphics products in the industry,” shares Ebenger.

Magnetic Strip Options Adams stocks flexible magnetic strip in widths from .25 to three inches. “We can cut or score pieces as short as .25 inches and provide rolls up to 1,500 feet depending on material thickness,” shares Martin.

Magnum Magnetics magnetic strip is available plain or with different surfaces. Choose vinyl or add foam, indoor or outdoor adhesive backing to create magnetic tape. Standard thicknesses range from .025 to .250 inches.

Standard widths are .5, .75, one, 1.5, two, and three inches.

Master Magnetics provides magnetic strips with and without adhesive in various widths and thicknesses to the market.

New Force offers flexible magnetic strips in widths from .5 to four inches wide as standard.

Newlife Magnetics’ high-energy strip can offer the holding force of a standard energy magnet strip of nearly twice the thickness, shares Amburn.

Xcel Products offers flexible magnetic strips. The material is domestically produced with a high-quality permanent adhesive.

Magnetic Magnitude

Magnetic media includes printable magnetic and magneticreceptive options to flexible magnetic strips that add holding strength to a printed application.

The opportunity for all three categories, specifically in the wide format space, is great thanks to their versatility. D digitaloutput.net

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by Digital Output Staff

here is a need for speed in today’s society where everyone wants something yesterday. Why should printing be any different?

Print service providers (PSPs) with textile printing capabilities turn to high-speed dyesublimation (dye-sub) printing when production volumes necessitate quick turnaround over large runs. These wide format printers are equipped with the correct combination of digitaloutput.net

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printheads, ink technology, and other mechanisms to minimize downtime and increase throughput.

Define High Speed

that range from 4,000 to 14,000 square feet per hour (sf/h) for a variety of applications.”

Mike Syverson, textile manager North America, Durst US, says “high speed” is a relative term. “A range of printer speeds are on the market.

Durst manufactures dye-sub systems

“We consider high speed as production dye-sub systems capable of producing high volumes of sellable-quality

So what is high-speed dye-sub? We asked vendors interviewed for this article to provide their definition.

At Mutoh America, Inc., high-speed printing is defined as the maximum speed topping out at over 1,000 sf/h, with production of at least 500 sf/h, says Tony Simmering, product manager, Mutoh.

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width, high speed would be considered 1,300 sf/h.

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finished goods in a day,” shares Tim Check, senior product manager, Professional Imaging, Epson America.

Jos Notermans, product manager digital printing, SPGPrints, cites high speed as a couple of 100 linear meters per hour. “With 1.6-meter wide paper this would mean above 3,400 sf/h. That gives a daily production of up to 4,000 meters per hour, which is really a production volume as it

1) Available through Canon, the DGI FH-3204 reaches speeds of up to 3,230 sf/hr. The printer is designed to run with either four colors or optionally six colors for fluorescent inks or orange/blue inks for expanded color gamut. 2) The Epson SureColor F10070 offers industrial-level printing.

results in up to one million meters per year.”

High speed means different things depending on the technology, i.e. single-pass printing versus scanning. “Normally high speed means about 150 square meters per hour for a scanningtype inkjet printer, this is about two meters per minute for a 1.2-meter width. To reach two meters per minute with a scanning inkjet at a minimum of four passes, it requires more than three sets of printheads for each color. This means higher manufacturing costs for faster production,” explains Juan Kim, CEO, Valloy Incorporated.

John Ingraham, senior specialist product marketing, Canon USA, Inc., quotes high-speed production as 2,000 sf/h or higher. “This is based on printhead technology and the number of printheads.

Typically, high-speed production systems incorporate eight or more printheads—Kyocera or Ricoh Gen 5—with native resolutions around 600 dpi or greater.”

Speed is also relative to print width. Victoria Nelson Harris, senior textile segment specialist, Mimaki USA, Inc., explains that she defines high-speed for less than 76-inch wide printers at 1,500 sf/h, whereas for grand format printers over ten feet in

From the perspective of Micol Gamba, senior manager product marketing, EFI Reggiani, a high-speed dye-sub printer produces at least 1,500 sf/h when considering a 71-inch width device.

Check cautions that print speed is just one factor impacting overall throughput. “Increasing uptime and reducing non-print time related to job processing, system maintenance, and inefficient movements can contribute greatly to throughput.”

Make It Speedy

A dye-sub printer reaches the aforementioned high speeds thanks to the right combination of printheads, media handling, and a host of other factors.

“The printhead type and the number of printheads are the

2

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most important. By putting the colors in symmetrical order in the carriage improves the speed, as the order of color laydown is then the same whether the carriage moves from left to right or from right to left. So this avoids the so called ‘soccer field effect’, banding in uniform areas of the printing,” explains Notermans.

Printheads are key elements in EFI’s case. “We have adopted established, high-end technologies that can then ensure very competitive cost per nozzles combined with very fast jettability performances, which are also ensured by a proprietary ink system and print engine software that bring the printhead to its maximum expression,” shares Gamba.

Simmering admits that “a lot of it is based on the printhead jetting speed in combination with the ability to dry the ink fast enough.”

#2

“The type of printhead, higher number of printheads, and higher number of nozzles the printhead has increases the speed of the printer,” adds Nelson Harris.

Kim agrees it depends on the printhead specifications. “Bandwidth of printhead, number of nozzles, number of printheads, and jetting frequency of printhead. But, ink also needs to flow smoothly to catch up with high speeds and sophisticated negative pressure control may be required.”

Yes, Notermans seconds a consideration of the ink system, “inks need to be of high quality to avoid blockages or other print quality causing problems.” digitaloutput.net

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#5

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3 While printheads and the ink are notable, there are other components of note. “Media handling, color configuration, and more all impact the print speed of a given platform. However, there are factors to consider such as downtime due to roll changeover, maintenance, and overall reliability,” notes Syverson.

printers work with jumbo rolls and need stronger systems to handle the larger media,” explains Ingraham.

“Media handling must be able to keep up with the printing speed but decent design makes this possible,” admits Notermans.

Media handling is important and how it is integrated influences speed. “High-speed production

“A high-speed print system is an optimized collection of system components that work efficiently together,” adds Check, which

INFO# COMPANY 145 Canon USA, Inc.

WEBSITE csa.canon.com

companies mentioned

See page 21 for more info.

146

Durst US

durstus.com

147

EFI

efi.com

148

Epson

proimaging.epson.com

149

Mimaki USA, Inc.

mimakiusa.com

150

Mutoh America, Inc.

mutoh.com

151

SPGPrints

spgprints.com

152

Valloy Incorporated

valloy.com

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is why Epson as a vertical manufacture designs all components of the print solutions—printheads, ink chemistry, processor design, software, and image processing to work seamlessly and efficiently to produce volumes of finished goods.

equipment—and associated large capacity heat presses—is at the upper end of the scale,” explains Syverson.

Simmering notes that “highspeed dye-sub printers are

Beneficiaries of Quick

Print providers familiar with dye-sub are the best candidates for high-speed printers.

“The companies benefiting the most from a high-speed system are, generally speaking, already producing some level of work with dye-sub, as the cost of the

3) SPGPrints Rose textile printer. 4) The Mutoh ValueJet 1939TX is a highly efficient textile device.

5) EFI Reggiani NEXT Plus is an industrial, beltless digital printer that prints on paper for transfer and non-elastic fabrics with up to eight colors.

4

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important for print providers looking at scalability. Purchasing a high-speed printer allows shops to have high production at a relatively low entry cost.”

“High-speed production printers are ideal for print providers looking to upgrade their fleet of existing dye-sub printers to a single printer and outsourcing a large volume of dye-sub work.

Since the pandemic, turnaround times for outsourced work has increased from a week to four to eight weeks or longer. Bringing the work in house makes it possible to bring in more business and meet customer critical deadlines,” explains Ingraham.

But, not every print shop requires a high-speed dye-sub printer. “Higher speed brings higher production rates, but flexibility should be considered.

If it is a similar cost for multiple, slower speed printers than a single, high-speed printer, sometimes it is better to have multiple printers for more flexibility and safe backup when a printer is

malfunctioning,” explains Kim.

According to Nelson Harris, “the ecommerce print on demand sector is booming, localized manufacturing is being sought, 5 due to the frustration with supply chain issues printing overseas.

Expansion of onshore fulfillment centers and faster production speed combined with options to lower the cost of consumables, such as jumbo paper units and ten liter bulk ink systems, lower running costs, and higher return on investment,” are all contributing factors to an increased level of adoption of high-speed, dyesub printers.

Applications of Note

PSPs print via dye-sub to produce all sorts of end use applications, including decoration, apparel, and signage. High-speed dye-sub is advantageous for most of these, but some more than others.

Historically, Syverson says high-speed dye-sub printers are installed in textile printing companies that produce printed yardage of fabric for decoration, hospitality, and apparel.

“Traditionally it was mostly the sign and banner market but soon the sportswear market got interested as its polyester fabrics became better and digital allows for a lot of design freedom, an important factor in sportswear.

Nowadays other fashion items are made out of polyester so sublimation printing becomes attractive to them as well. The same counts for the home decoration market,” says Notermans.

Gamba agrees that “high-speed dye-sub printing is already showing significant benefits for applications like apparel, which represents approximately 70 percent of the textile digital printing world, but also sportswear, home décor, and soft signage.”

“In the last few years, we’ve seen tremendous growth in the

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trade show and retail sectors for fabric printing. This has given way to more PSPs bringing in large, industrial-level equipment to satisfy the demands of the market,” notes Syverson.

Simmering lists common applications for high-speed dye-sub printing like sports apparel, temporary fixtures like event tents, pop-up retail signage—“typically items produced in bulk where attention to extremely fine detail is not necessary.”

In the on demand sector, Nelson Harris says blank goods like blankets and floor mats are ideal for this technology. She also suggests textile converters who have in-house design agencies.

Need for Speed

Is speed the final consideration when determining which dyesub printer is right for the job?

No. But for many PSPs it might be what makes the most sense for them based on their daily, weekly, or monthly output and applications produced. D July 2023 | Digital Output { 17 }

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KEY

DS = Dye-Sublimation

A = Acid

PIGM = Pigment

AQ = Aqueous

REA = Reactive

CM = Contact Manufacturer

SUB = Sublimation

D = Disperse

TDS = Transfer Dye-Sub

DDP = Direct Digital Print

WB = Water-Based

DDS = Direct Dye-Sub

INFO#

KEY

Company/Website

100 Agfa agfa.com/na 101 Amica Systems amicasystems.com

102 Arioli arioligroup.com 103 Canon Solutions America csa.canon.com

104 ATP globalimaginginc.com/textile-printers

105 d.gen, Inc. dgen.com

106 DigiFab Systems, Inc. digifab.com

107 Durst Image Technology US LLC durstus.com

108 EFI efi.com

109 Epson proimaging.epson.com

110 FTEX ftex-co.com

111 Gandy Digital gandydigital.com 112 HP Inc. hp.com

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Max. Speed (sf/h)

Max. Max. Width Resolution (Inches) (dpi)

List Price (U.S.)

Product

Print Process

Ink Type

Avinci CX3200

TDS, DDS

WB DS

2,906

126

600x1,800

CM

XB18 CR33 SW16 XBM18/XBM20 CW33 FR19 ArioPrint

DDP DDP DS DDP DS DS DDP

WB D, A, REA Dye; WB PIGM WB D, A, REA Dye; WB PIGM WB WB D, A, REA Dye; WB PIGM DS DS REA, D, A

CM 1,850 700 211.9 1,389 CM 1,500

70 126 63 75.9 130 75 78

CM CM 1,200x600 600 1,200x600 600x600 1,200x1,200

CM CM CM CM CM CM CM

DGI FT-3204X DGI FH-3204 DGI Poseidon DGI Poseidon MS JP4 180 MS JP4 320 OnPaper 1900 OnPaper 2600 OnPaper 3300 OneTex 1900 OneTex 2600 OneTex 3300 OneTex 5200 Artrix H8 Teleios Hexa Arachne Hexa Papyrus G5 Teleios Grande H12 Papyrus Grande StampaJet XP-64 StampaJet EN-64 StampaJet K8-190 StampaJet K2-190 StampaJet K4-190 StampaJet EN-75 Rhotex 500 Alpha 190 Alpha 330 P5 Tex iSUB Reggiani BLAZE Reggiani ecoTERRA Gold Reggiani TERRA Silver Reggiani TERRA Gold Reggiani TERRA Platinum 180 - 240 -340 Reggiani TERRA Titan 180 - 240 - 340 Reggiani POWER 180 - 240 - 340 Reggiani NEXT Plus 180 - 340 Reggiani HYPER 180 -240 -340 Reggiani VOGUE Reggiani COLORS 180 - 240 -340 Reggiani BOLT VUTEk FabriVU 340+ VUTEk FabriVU 340i+ VUTEk FabriVU 520 COLORS 340 POWER 340 VUTEk D3r VUTEk D5r VUTEk 3r+ VUTEk 5r+ Pro 32r+ VUTEk Q3r VUTEk Q5r SureColor F570 Pro SureColor F6470 SureColor F6470H SureColor F7200 SureColor F9470 SureColor F9470H SureColor F10070 SureColor F10070H Monna Lisa 8000 JS BT-180 JSF 400 JS FT-180 JK-300 JS RP-320 NextJet Paper NextJet Direct HP STITCH S500 Printer HP STITCH S1000 Printer

TDS, DDS TDS, DDS TDS TDS TDS, DDS TDS, DDS TDS TDS TDS TDS DDS DDS DDS DDP DDP DDP TDS DDS DDS DDS, DDP DDS, DDP DDS, DDP DS DS DDS, DDP DDS, DDP DDS, DDP DDP DDS, DDP, TDS CM CM CM CM CM CM CM TDS, DDS DDP, TDS, DDS DDP DDP DDP TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS DDP DDP DDP DDP DDP DDP DDP TDS TDS TDS TDS TDS TDS TDS TDS DDP DDP DDP DDP DDP DDP TDS DDS DDP, DDS DDP, DDS

DS DS DS DS DS DS AQ DS AQ DS AQ DS AQ DS AQ DS AQ DS AQ DS PIGM DS, PIGM, REA PIGM, REA, A, DS SUB DS, WB DS A, REA, D, PIGM, SUB A, REA, D, PIGM A, REA, D, PIGM, SUB SUB, PIGM SUB, PIGM A, REA, D, PIGM WB D DS WB, PIGM, REA, D, A, SUB WB, PIGM, REA, D, A, SUB WB, D, DS WB D/DS, DD, A, REA, PIGM WB PIGM WB PIGM WB PIGM WB PIGM WB PIGM WB D/DS, DD, A, REA, PIGM WB D/DS WB D/DS, DD, A, REA, PIGM WB D/DS, DD, A, REA, PIGM WB D/DS, DD, A, REA, PIGM WB REA WB D/DS WB D/DS WB D/DS WB D/DS WB D/DS LED LED LED LED LED LED LED DS DS DS DS DS DS DS DS A, D, PIGM, REA A, REA, D, PIGM A, REA, D, PIGM PIGM, REA, A A, REA, D, PIGM SUB, PIGM, REA, A WB DS WB DS DS DS

2,690 3,230 2,648 2,260 3,120 4952 1,668 2,152 2,690 1,668 2,152 2,690 3,875 775 775 560 1,485 CM 1,076 1,010 1,010 3,767 2,718 3,261 2,190 3,300 10,655 15,820 4,120 2,045 3,498 2,045 3,498 7,685 14,854 14,854 4,036 33,906 3,498 7,685 87,188 5,172 2,691 4,800 9,149 16,835 2,196 2,626 4,370 5,242 2,756 6,006 7,233 CM 820 400 634 1,169 1,169 2,700 2,635 1,744 1,615 CM 861 1,615 753 3,552 2,583 CM CM

124 126 74 64 70.8 126 74 102 126 74 102 126 208 CM 74 74 74 126 130 63.3 64 74 74 74 74 198 75 130 133 71 71 71 71 71/95/134 71/95/134 71/95/134 71/134 71/95/134 71 71/95/134 71 133 133 205 134 134 138 205 138 205 126 138 205 24 44 44 64 64 64 76 76 72 71 126 71 126 126 74 208 64 126

720x1,440 600x1,200 600x1,200 600x1200 600x600 600x600 2,400 2,400 2,400 2,400 2,400 2,400 2,400 1,200 1,200 1,200 2,400 CM 2,400 1,440 1,440 600x1,200 600x1,200 600x1,200 1,440 600 600 600 800 2,400 2,400 2,400 2,400 2,400 2,400 2,400 2,400 2,400 2,400 2,400 4,800 2,400 2,400 2,400 2,400 2,400 1,200 1,200 1,200 1,200 847 1,200 1,200 2,400x1,200 1,200x600 1,200x600 1,440x720 1,440x720 1,440x720 1,200x1,200 1,200x1,200 1,200x1,200 1,440 1,200 1,440 600x1,200 1,440 2,400 2,400 1,200 1,200

CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM $38,900 $49,900 CM $74,900 $93,900 $69,900 CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM $2,895 $8,195 $8,695 $16,995 $28,995 $32,995 CM CM CM CM CM CM CM CM CM CM CM CM

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113 Kornit Digital kornit.com

114 Kyocera Corporation global.kyocera.com 115 Mimaki USA, Inc. mimakiusa.com

116 Mosaica Group (The) get.printmosaica.com/panthera

117 MS Printing Solutions msitaly.com

118 MTEX NS, S.A. mtexns.com 119 Mutoh America, Inc. mutoh.com

120 Roland DGA Corporation rolanddga.com 121 SCG Digital America Inc. scg-america.com 122 SPGPrints spgprints.com

INFO#

123 StratoJet stratojetusa.com 124 Valloy Incorporation valloy.com 125 Zimmer Austria zimmer-austria.com

Company Name

130 Aeoon Technologies

Website

aeoon.com

Max. Max. Width Resolution (Inches) (dpi)

List Price (U.S.)

Product

Print Process

Ink Type

Presto Presto S Presto MAX Presto MAX S FOREARTH

DDP DDP DDP DDP DDP

WB PIGM WB PIGM WB PIGM WB PIGM WB PIGM

2,862 5,400 2,628 5,103 2,690

70.8 70.8 70.8 70.8 70.8

1,000x800 1,000x800 1,000x800 1,000x800 600x600

CM CM CM CM CM

TS100-1600 TS500P-3200 TS55-1800 TX300P-1800 MkII TX300P-1800B TX500P-3200DS Tiger-1800B MkIII TS330-160 Panthera S2-1.8m Panthera S2-3.2m Panthera S4-1.8m Panthera S4-3.2m Panthera S4-1.8m Panthera S4-3.2m Panthera JR JP4 EVO JP7 JPK EVO 180 JPK EVO 320 Dragon Eagle Falcon RJ900X ValueJet 1948WX ValueJet 1938WX ValueJet 2638WX XpertJet 1682WR XpertJet 1642WR Pro ValueJet 1938TX Texart RT-640 Texart RT-640M Texart XT-640 SUPRAQ 3200-TX6 GD1800AE-FP GDHT180-E2 Violet Jasmine Magnolia Rose PIKE Piranha XT-500 Pro Piranha XT-1000 Pro TOPAZET 70R TX

TDS TDS TDS DDP, DDS, TDS, DDP, DDS DDP, DDS DDP, TDS, DDS TDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS, DDS TDS TDS DDP TDS TDS TDS TDS TDS TDS DDP, DDS TDS TDS, DDS TDS DS DDS DDP DDP DDP DDP TDS DDP DS DS DDS, DDP

DS DS DS SUB, D, PIGM, REA, A, A, D, PIGM, REA, SUB, SUB REA, SUB DS DS, D DS, D DS, D DS, D DS, D DS, D DS, PIGM AQ, D, DS AQ, D, DS, PIGM, REA, A AQ, D, DS, PIGM, REA, A AQ, D, DS, PIGM, REA, A SUB SUB PIGM AQ AQ AQ AQ AQ AQ A, AQ, D, PIGM, REA, WB DS DS DS DS DS REA, A, PIGM REA, PIGM REA, PIGM REA SUB REA DS DS Dye, REA, A, PIGM

753 1,937 1,453 710 732 1,399 4,144 1,453 1,500 2,000 3,000 4,000 1,800 2,000 1,900 4,682 6,000 12,000 12,000 2,949 6,566 1,636 676 2,199 1,327 1,168 1,012 1,325 914 522 522 1,098 614 592 668 1,650 9,257 6,889 7,750 71,688 677 700 550

64 130 77 76 75 130 75 64 72 126 72 126 72 126 74.8 125 70 70 126 75 126 126 44.6 74.8 74.8 103.6 63.6 63.6 74.8 64 64 64 128 72 72 70.9 72.8 72.8 72.8 72.8 72.0 126.0 71

900 1,080 1,200 1,440 1,440 1,080 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 720x2,400 600x600 600x600 600x600 600x600 720 1,440 1,440 2,880 1,440 1,440 1,440 1,200 1,200 1,440 1,440x1,440 1,440x1,440 1,440x1,440 400 1,440 1,440 720x1,080 600x2,400 1.200x1,200 300x1,200 1,200x1,200 2,400 2,400 1,200x900

CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM $7,560 $49,995 $31,995 $49,995 $26,495 $19,995 $39,995 $19,995 $19,995 $29,995 CM CM CM CM CM CM CM CM CM CM $45,000

Colaris

DDP

REA, D, A, PIGM, SUB

5,150

86, 102, 134

1,600

CM

Product Name

Compact Series Kyo Series Maikuro 131 Amica Systems amicasystems.com TS1519 TSD1519 TSA1416 TSDX 132 Brother International Corp. brotherdtg.com GTXpro GTXpro Bulk GTX600 GTX600 Extra Colors 133 DTG Connection dtgconnection.com DTG-C Model X DTG- Model X2 134 Epson proimaging.epson.com SureColor F2100 SureColor F2270 SureColor F3070 135 Kornit Digital kornit.com Storm Series Avalanche Series Atlas Vulcan

Max. Print Area (Inches) Custom Custom 15x17 15x19 15.7x19.7 15.7x19.7 43.3x31.5 16x21 16x21 24x24 24x24 16x20 16x20 16x20 16x20 16x20 20x28 23.5x35 23.5x35 28x39

INFO#

INFO#

Company/Website

Max. Speed (sf/h)

Company Name

136 Lawson Screen & Digital

137 MESA by ColDesi 138 OmniPrint International

139 Polyprint USA 140 Ricoh DTG

141 Roland DGA Corporation 142 ROQ

Website

golawson.com

Product Name

Diamond-Jet DTG Express-Jet DTG Zeus Digital Hybrid Epson SureColor F-2100 Epson SureColor F-3070 dtgprintermachine.com DTG G4 - Vacuum Platen omniprintonline.com Freejet 330 TX Freejet 330 TX Plus OmniPrint i12 OmniDTF Cheetah polyprintusa.com TexJet echo2 ricoh-dtg.com RICOH Ri 1000 RICOH Ri 2000 RICOH Ri 100 rolanddga.com VersaSTUDIO BT-12 Texart XT-640S roq.us ROQ Hybrid ROQ NOW

Max. Print Area (Inches) 16x20 16x20 18x18 16x20 16x20 16x20 12.5x22 12.5x22 16x20 CM 16x20 16x24 16x19.6 16x19.6 8.27x11.69 (A4) 11.5x8 (A4) 53x64 29x35 17.7x13.4

#10

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#12

#13

#14

#15

#16

#17

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PAGE

INFO#

ADVERTISER

WEBSITE

12 Alpina Manufacturing, LLC

20 fastchangeframes.com

13 Alpina Manufacturing, LLC

20 bannergrip.com

14 Budnick Converting/Banner Ups

20 bannerups.com

15 Delivery Signs

20 yardsignsresellers.com

16 DGS - Digital Graphic Systems Inc. 20 dgs-usa.com

Floor Graphics State of the Industry Large Format Viewpoint

2 Durst US

15 durstus.com

3 FDC Graphic Films, Inc.

11 fdcfilms.com/3522

4 Fellers

27 fellers.com

5 Flatbed Tools

15 flatbedtools.com

6 ImagineThis

2 imaginetr.com

17 Neenah Inc.

20 neenahpaper.com

7 Newlife Magnetics, LLC

9 newlifemagnetics.com

8 Panel Processing

7 panel.com

9 Signs365

28 signs365.com

INFO#

And More!

9 ddp.us 19 dtg-c.com/domag

COMPANY

170 Aberdeen Fabrics, Inc.

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PAGE

Textile Ink

1 Digital Dolphin Products 10 DTG Connection

22

187 Adams Magnetic Products Co.

8

145 Canon USA, Inc.

13

160 CMYUK

6

180 Colex Finishing, Inc.

25

181 Cutworx USA

25

146 Durst US

13

161 EFI

6

147 EFI

13

148 Epson

13

171 Fisher Textiles

22

172 Greentex America

22

188 Magnum Magnetics Corporation

8

189 Master Magnetics, Inc.

8

149 Mimaki USA, Inc.

13

150 Mutoh America, Inc.

13

190 New Force Magnetics Co.

8

191 Newlife Magnetics LLC

8

173 Premex Solutions, Inc.

22

174 RePatriot Flag, LLC

22

175 Serge Ferrari

22

151 SPGPrints

13

162 UFabrik

6

176 UFabrik

22

177 Ultraflex Systems, Inc.

22

152 Valloy Incorporated

13

192 Xcel Products, Inc.

8

182 Xcel Products, Inc.

25

163 Zund America, Inc.

6

183 Zund America, Inc.

25

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by Melissa Donovan

number of reasons exist to turn to sustainable-minded products in our daily lives, whether it’s for work or personal choice. On the production �loors of wide format print shops, businesses work with materials that are considered “green” to help the environment and meet their customers’ eco-commitments.

When it comes to printing textiles, there is a selection of products from a handful of { 22 } July 2023 | Digital Output

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vendors made up of recycled single-use plastic waste or other recycled components.

Recycled vs. Virgin

Textiles made from recycled single-use plastic waste or other recycled components are becoming more important for a number of reasons.

“Textiles are the number one contributor to microplastics in our environment. User recycled

content is a great step in a reduction of the seriousness of microplastics,” shares Ken Bach, business development manager, Aberdeen Fabrics, Inc. Using textiles made up of recycled components is a huge contributor to reducing waste.

Above) UFabrik offers products using accredited recycled yarn, specifically yarn produced from recycled single waste PET plastic waste.

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“On average 80 percent of plastic bottles end up in a land�ill. Using materials made out of recycled polyester is important to reduce and ultimately stop plastic ending up in land�ills or our oceans,” shares Grainne Brennan, head of sustainable products, Premex Solutions, Inc. Supporting the use of fabrics made of recycled components is good practice. “It minimizes the number of water bottles and other plastics from land�ills and oceans. This aids in conserving natural resources such as oil and water needed to produce virgin polyester,” explains Scott Fisher, president, Fisher Textiles, Inc. “Recycling reduces the need for virgin materials, which help to conserve natural resources and reduce energy consumption and greenhouse gas emissions associated with extraction and production,” adds Steven Amitai, GM, Greentex America.

The move to fabric made from recycled content supports a circular economy. “With the introduction of another source of raw �iber—domestically harvested, recycled plastic—there is hope that the material supply chain will diversify enough to interrupt the historical trend of price spikes, supply shortages, and politically motivated trade interference,” notes Mike Glaser, co-founder, RePatriot Flag, LLC. Brett Platt, textiles business manager, UFabrik, sees demand for environmentally responsible, high performing, wellpriced materials from global brands that meet sustainability digitaloutput.net

DO_23_7-1_FabricRevFinal-SWMD.indd 23

goals. “All of us need to develop solutions that consider their environmental impact.”

Understanding Standards

A number of programs certify and verify whether a fabric is made from recycled components like single-use plastic waste.

One is the U.S.-based REPREVE from Uni�i, Inc. Made from recycled plastic bottles, REPREVE yarns include FiberPrint tracer technology, which analyzes and validates the REPREVE �iber content. A third-party laboratory through the U Trust veri�ication program evaluates the fabric and determines the amount of REPREVE polyester.

“To be considered a REPREVE textile, the product must contain a minimum of 30 percent REPREVE yarn. This means at least 30 percent of the material used to make the textile must be made from recycled plastic bottles using the REPREVE FiberPrint technology,” continues Fisher.

Uni�i issues a certi�ication number and certi�icate annually. “This provides accountability in the supply chain and allows customers to verify that the product they purchase is made from sustainable materials,” says Fisher.

“The REPREVE program is revered because it provides a traceable and certi�iable way to verify that a product contains recycled content,” seconds Amitai.

Companies like UFabrik offer products using accredited recycled yarn, speci�ically yarn

produced from recycled single waste PET plastic waste, but it isn’t necessarily accredited by Uni�i or uses REPREVE. According to Platt, UFabrik is a fully certi�ied range, “which is a vital component in the procurement and speci�ication process.”

Another certi�ication method is the Global Recycled Standard (GRS) facilitated by the non-pro�it Textile Exchange. GRS in1 cludes a higher—50 percent—minimum recycled content percentage and additional social and environmental requirements related to processing and chemical use. A professional, third-party certi�ication body audits each stage in the supply chain to allow a product to be labeled with the GRS logo.

“Using a certi�ied recycled yarn—whether it be REPREVE or GRS certi�ied—helps monitor how yarns are processed and acquired. This is an integral part of providing recycled content products. It validates and sets a standard for all suppliers to follow,” explains Kylie Schleicher, director of product development and product management, Ultraflex Systems, Inc.

Ultra�lex categorizes its ReSource materials as those that are made with 100 percent GRS certi�ied recycled yarns. “We do have other materials that contain about ten percent recycled yarns,

but we do not qualify it as our ReSource, recycled yarn materials,” notes Schleicher.

Serge Ferrari is another example.

As a European manufacturer, it utilizes high-quality, highly regarded European-made products in its Seemee Loop Mesh and Front portfolio.

“All polyester chips, yarns, and fabrics used in the manufacturing of all Loop products are GRS certi�ied according to GRS 4.0. It is certi�ied that the PET chips/ yarns/fabrics are made from 100 percent post-consumer waste,” shares Dr. Peter Siemens, R&D director, Serge Ferrari.

Fabric Type

Polyester and polyester-based fabrics are common contenders

1) Fisher Textiles’ ETP 4310 Uni is an apparel fabric for athletic uniforms. Made with 100 percent REPREVE and 100 percent post-consumer waste, it contains 20.5 water bottles per linear yard and is compatible with dye-sublimation transfer printing.

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than products made with virgin yarns,” adds Schleicher.

Glaser says that in this vein, if a customer has to pay more for a product, it should be a quality product, in so much that durability and colorfastness be improved upon over its prior form. Although, he notes that the price difference between virgin polyester and recycled polyester is shrinking.

2 for textiles made from recycled components, this is because plastic bottles essentially become sustainable polyester.

Other �ibers like nylon and spandex are incorporated with recycled components during manufacturing, admits Fisher.

Natural �ibers like cotton are generally not compatible—speci�ically in relation to REPREVE, according to Amitai, “because the process used to create the recycled polyester �iber requires high heat.”

Brennan says that it’s possible to incorporate recycled polyester into linen. For example, Premex Solutions offers a product that is 48 percent REPREVE polyester, 44 percent polyester, and eight percent linen.

companies mentioned INFO# COMPANY 170 Aberdeen Fabrics, Inc.

Bach notes that other fabrics can utilize recycled polyester, “but that limits or eliminates the opportunity for polyester pure recycling. In this case, it is best to keep the product 100 percent polyester contact.”

Despite Drawbacks

While there are advantages of using a textile made up of recycled content, there are also some disadvantages.

REPREVE textiles do cost more than both their non-certi�ied and virgin component counterparts.

“This is due to the proprietary manufacturing process and certi�ication offered by REPREVE,” explains Fisher.

“Products made with GRS certi�ied yarns are more expensive

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premexsolutions.com

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RePatriot Flag, LLC

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As a result, “print providers may be able to charge more for applications using REPREVE textiles, but the decision ultimately depends on market demand and the perceived value of sustainable products to their customers as well as their commitment to the environment,” admits Amitai.

“REPREVE yarns cost around 20 percent more than standard polyester counterparts. Therefore, this is re�lected in the price, which can be demanded from providers of REPREVE textiles,” suggests Brennan.

Luckily, there are really no other caveats to be aware of like ink compatibility or dot gain, wash fastness, or handling. And if there are any challenges, “companies like Greentex provide guidelines and recommendations for handling and printing to help ensure optimal results,” says Amitai.

“Generally speaking, no special handling is needed. Print and ink compatibility is the same as regular polyester,” shares Fisher.

2) Visual representation of how UFabrik converts post-consumer waste to its fabric.

“We have found there to be no difference in performance, printability, handle, or wash fastness when compared to virgin polyester fabrics. The only difference we have seen is the shade of the cloth. As the yarn is produced from recycled plastic there is a blue tint to the shade of the cloth,” says Brennan.

“The only difference between recycled versus virgin polyesterbased fabrics is the color white point has a slightly darker L* value,” adds Bach.

Glaser says that certain fabrics—while they include recycled components and meet standards put forth by companies like REPREVE—may not meet the necessary standards of the application in question.

“REPREVE nylon cannot be used in the outdoor �lag industry, to date. The luster type of the nylon created by Uni�i—semi-dull and dull—does not possess the required UV resistance to be useful for long duration, outdoor exposure. Should there become a bright luster version of REPREVE nylon, it would have the potential to change the face of the �lag industry as we know it,” acknowledges Glaser.

Fabric Does its Part

Consider working with textiles consisting of recycled versus virgin components the next time you quote a job. There are a variety of reasons to do so from minimizing what goes into land�ills and the ocean to conserving natural resources. Visit digitaloutput.net/ webinars to view a recent broadcast on the topic. D digitaloutput.net

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by Digital Output Staff

any printers are familiar with magnetic and magnetic-receptive media options. However, when you consider all of the heavy metal involved in finishing, one might wonder what possible challenges could pop up.

“Magnetic material is relatively easy to work with and can be cut easily. However, the proper blades and settings are required,” says Brian Ebenger, VP, business development, Xcel Products, Inc. digitaloutput.net

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Raum Divarco, GM, Cutworx USA, insists that the application is always one of the key factors for any project—magnetic or not. He points out that when finishing magnetic and magnetic-receptive materials, brand, thickness, and intended cut process should be considered. “For example, maybe the available finishing platform is a traditional platen-style die cutter. If the material is magnetic or magnetic receptive, you may have to take steps to minimize the material wanting to stick to the platen plate.”

For digital die cutting machines, Divarco recommends considering the type of tooling used. “While these materials are generally relatively thin, they can wear out low-grade blades. If your project is for more contour cut shapes you may need to consider if blades will cause a raised edge—otherwise known as a lip—along the cut. Some of these results may be unacceptable for your customer. There Above) Zünd cutters equipped with a Zünd UCT are able to cut any thickness of magnetic foil with a drag blade at full machine speed—40 in/s.

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are options for asymmetrical tools that significantly reduce the raised edges on thicker materials.”

Additional considerations may come into play if the magnetic vinyl has adhesive mounted to it.

“Certain adhesives might require your operation team to occasionally clean the blade. This is to minimize drag force from friction as well as reduce tracking adhesive residue,” adds Divarco.

According to Sara Marshall, applications specialist, Zund America, Inc., with a Zünd digital cutting system, cutting printed magnet foil is easy. “Even if the material comes off a roll, the vacuum system provides the necessary hold down to keep it flat and enable precisely cut edges with very minimal bleed.” She adds that Zünd digital cutting/routing systems are capable of cutting any material—short of plate glass and steel—including magnetic and magnetic-receptive solutions.

Magnetic-receptive options aren’t magnetized when printed, so they won’t stick to metal. But, Ebenger points out they tend to be thinner and lighter than magnetic materials.

layout is set up to be common cut for smaller pieces, you might need to make sure your vacuum zones are optimized. Smaller pieces on what can be more rigid type materials may slide around.

An option to minimize parts shifting could be depth control to allow the pieces to be stripped out of the sheet. Your operation team could also consider putting down magnetic sheets as the cutting underlay. For smaller pieces or sets of images this can assist in collating when the sheets come off the table.”

Recommended Tools

Several finishing tools are well suited for magnetic and magnetic-receptive media options including a router; die cutter; digital cutting system; and manual cutters, knives, and scissors.

“Tangential drag knife cutting tools would be some of the most commonly used for cutting magnetic materials. There are various profiles, grades, and thicknesses to choose from for every project,” shares Divarco.

“Magnetic-receptive materials are generally thin and the volume of the job and the setup of the layout might require some extra thought,” agrees Divarco. “If the

To cut printable magnet foil, Marshall says customers will use a Zünd Universal Cutting Tool (UCT) with a standard drag knife (type Z10) blade. “The tungsten carbide blade easily makes its way through the material on common shapes, complex contours, and tight edges. This material can

INFO# COMPANY 180 Colex Finishing, Inc.

WEBSITE colex.com

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Cutworx USA

cutworxusa.com

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xcelproducts.com

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be cut at the maximum speed of 40 inches per second (in/s).”

Of all the options, Divarco notes that router and laser cutting are the least practical. “Router cutting can work but is prone to being messy. This is especially true with adhesive-backed materials. There will be shavings and other potential sticky debris and the processing speeds are much slower than using knife blade tools. Overall, it is a poor choice in the process for this application.”

Marshall adds that other blade and tool options can be recommended depending on the thickness of the material and the complexity of the shapes; however, Zünd does not recommend using a laser to cut this type of material.

“Laser processing for this application is not recommended in my opinion. Certain materials shouldn’t be laser cut depending on their composition. You can get burning, melting, and various other effects that are easily avoided with a knife cutting system,” suggests Divarco.

Thickness Considerations

Of course, the thickness or thinness of the material affects which tool should be used and at what setting.

“All settings impact the cutting of the material so the gauge will play a critical role in the success of the material,” says Ebenger.

Thicker materials typically need a robust cutting solution, adds Divarco. “The thin blades used on

thin sheets for contour cuts might not have too much resistance or deflection at .015 inches. The same thin blade might struggle to process materials when the thickness gets to .06 inches. The thicker the material gets, you may need to manage overcuts in interior corners for contour shapes.”

Divarco adds that some tooling options, like asymmetrical tools, help keep cuts smooth on thicker materials.

For larger volume runs Divarco suggests exploring partial depths of cuts similar to kiss cutting.

With depth control and the fairly dense nature of the materials, you can easily strip out most of the pieces from the sheet. “This helps manage cycle times for sheets on and off the table.”

Finishing Magnets

The Colex Finishing, Inc. Sharpcut Flatbed Cutter can easily cut magnetic material. It is capable of cutting up to 64 inches wide and up to two inches thick offering versatility, speed, and price.

Among its cutters, Cutworx Miura XY cutters are well suited for cutting flexible magnetic and magnetic-receptive materials.

Zünd cutters equipped with a Zünd UCT are able to cut any thickness of magnetic foil with a drag blade at full machine speed—40 in/s.

Magnificent Magnets

When it comes to finishing magnets, considerations for thickness and material composition should be top of mind. D digitaloutput.net

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