9 } Eye-Catching Signage
Display and POP
Past,
Melissa Donovan
18 } Liquid Laminating
Protect your digitally printed applications. by Cassandra Balentine
23 } Loading and Unloading with Ease Automated Board Handling Environments Reduce downtime and enable faster turnaround. by Cassandra Balentine
Wide format digital print has its origins in display and point of purchase (POP) applications, as they were one of the first items printed with the technology. We’ve come a long way, with initial projects in longer runs, printed with aqueous ink sets.
We’ve come a long way, with initial projects in longer runs, printed with aqueous ink sets.
Today’s display and POP graphics encompass not only a range of ink types from UV/UV-curable to resin/latex and even dye-sublimation, but also a variety of applications. Floor graphics, end caps, backlit signage, and silicone edge graphic displays are just a few examples.
Our cover story, Eye-Catching Signage, looks at the state of display and POP today. What are vendors seeing in this segment of the market in regards to application trends, customer demand, and challenges?
Elsewhere in this issue we tackle lamination, automated board handling, and feature a chart focused on floor graphics.
Film-based lamination is a well-established finishing method in the wide format space. However, UV LED curing is an emerging technology, particularly for applications like wallcoverings, fleet graphics, banners, and posters. Read more in Liquid Laminating.
Loading and Unloading with Ease gets into the popularity of automated board handling in the digital print market. Two of the biggest draws to implementing this technology into a print shop—it requires less operator intervention and provides increased productivity.
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Part 2 of 2
by Significans Automation
Signi�icans Automation leverages arti�icial intelligence (AI) to enhance and streamline work�low processes for its print and packaging print clients. Our approach involves integrating various AI technologies to enhance ef�iciency, reduce errors, and improve overall productivity. This is traditionally based on the type of AI currently used—narrow, general, or superintelligent.
We utilize narrow AI to automate narrowly de�ined sets of tasks within the work�low. For example, AI can handle repetitive tasks such as prepress checks, layout optimization, and smart ganging, as well as work�low management. This not only reduces the need for manual intervention but also ensures consistent and accurate results, which translates to faster turnaround times, huge capacity gains, and lower operational costs for our clients.
With general AI, we simulate thought processes within the work�low by reverse-engineering production processes. This involves using a series of conditional statements to automate decision-making tasks. For instance, during the pre�light stage, AI automatically cleans up and �ixes �iles before they proceed to production, ensuring they meet quality standards without manual intervention.
Our custom solutions leverage superintelligent AI to perform tasks at speeds beyond human capabilities, particularly in work�low computing speed. This allows for faster
processing of large volumes of data, enabling quicker turnaround times and improved print production ef�iciency.
We deploy two speci�ic AI technologies into our work�lows Patterning and ChatGPT. Patterning (or Aggregate AI with Advanced Logic), has pattern-recognition capabilities to identify trends and anomalies in print jobs. This approach allows us to analyze large datasets to identify patterns and make informed decisions. It helps convert legacy data and optimizes work�lows. We use ChatGPT as an internal tool to enhance the accuracy and reliability of our solutions. It supports our development processes and can be used by our customers in the same way.
Examples of how printers bene�it from the use of AI include implementing advanced AI algorithms for better nesting and layout optimization, reducing material waste and improving ef�iciency; applying AI to gather insights and optimize decisions, enhancing overall effectiveness; and predicting potential issues before they arise.
To learn about speci�ic AI applications deployed by Signi�icans Automation, check out Digital Output’s September issue, where examples of AI used for pre�lighting as well as applying marks to layouts for �inishing tasks are discussed.
For an assessment of your work�low software systems and how AI can complement them, call Signi�icans Automation at 877-463-4465. D
by Melissa Donovan
Thinking of printing to textiles? Well, current options are endless. And luckily, dye-sublimation (dye-sub) or another dedicated textile printer is not required to enter the fray. Even better, there is greater accessibility to substrates compatible with multiple types of ink including UV/UV-curable, resin/latex, eco-solvent/solvent, and sublimation.
Depending on the coating technology, one fabric may be able to run on one or more device in a print environment.
Pros and Cons
There are a number of advantages for print providers when it comes to utilizing textiles optimized for digital printing with multiple types of ink including UV/UVcurable, resin/latex, eco-solvent/solvent, sublimation, pigment, and dye.
Versatility is probably the biggest. “Textiles optimized for digital printing with multiple ink types allow print providers to offer a range of products. They produce everything from banners and �lags—using UV and resin inks for outdoor durability; to soft signage and apparel—using sublimation inks for vibrant colors on polyester fabrics,” explains Ken Bach, business development director, Aberdeen Fabrics, Inc.
SENFA offers multi-faceted fabrics and per its early 2024 press release, focuses on the fact that these are helpful for print providers looking for “simple stock management.” In other words, stocking one type of fabric printable with more than one ink versus multiple rolls per ink type, is cost ef�icient in regards to inventory.
Textiles optimized for digital printing with multiple ink types allow print providers to o er a range of products.
—
Ken Bach, business development director, Aberdeen Fabrics
On the �lip side, there are challenges with utilizing textiles
optimized for digital printing with multiple ink types.
Cost is one. “Utilizing multiple types of inks can increase production costs. Each ink type may have different price points, and the equipment required for handling different inks may add to initial investment and operational expenses,” suggests Bach.
Color matching is another. “Each ink type may have different color pro�iles and behaviors on different substrates. Achieving consistent color matching across various print jobs can be challenging and may require extensive calibration and testing,” admits Bach.
Textiles engineered to accept multiple types of ink are suitable for a range of applications.
Coming at it from the angle of which ink set is used, resin- and UV-based printers are ideal for outdoor and signage applications. “Textiles treated for UV and resin inks are highly durable and weather resistant. They are ideal for outdoor applications such as banners, signage, and flags that require longterm exposure to the elements without fading or degradation,” explains Bach.
Sublimation printing is well suited for soft signage, apparel and fashion, and even home décor and interior design.
UV inks are also ideal for home décor and interior design. “Both UV and sublimation printing can
Newlife Magnetics’ focus on science and engineering has led to our success in leading the magnet industry through research and development of exciting new products. We currently o er the thinnest, widest, lightest, and strongest magnetic materials on the market. Do you need a fresh way to display your graphics? Give our new Retail Pro a shot! Retail Pro is a micro-suction film that can adhere to various surfaces repeatedly. The versatility of our DCK makes this product great for almost any location, including, but not limited to, cars, windows, and countertops. DCK micro-suction film opens up a range of possibilities for consumers looking for convenient and e ective solutions for display purposes. To learn more visit newlifemagnetics.com. INFO# 18
Mutoh announces the new XpertJet (XPJ) C641SR Pro 24inch desktop eco-solvent printer/cu er combo. This printer is ideal for stickers, t-shirt transfers, vehicle signage and decals, labels, wall decals, posters, and banners. Print and cut a 24-inch roll of media and operate at speeds up to twice as fast as its closest competitors. The all-in-one XPJ-C641SR Pro benefits from Mutoh’s reliability and made in Japan quality, making it ideal for anyone to get into the print game. The XPJ-C641SR Pro with Mutoh GREENGUARD Gold Certified MS31 CMYK eco-solvent ink and the Genuine VerteLith RIP so ware, bundled with FlexiDESIGNER MUTOH Edition 21, is a $2,199 value. For more information or to request a free print sample, visit mutoh.com. INFO# 17
Best Value - Guardian Cold Laminator $4,295 Guardian Laminators are an a ordable, easy-to-use solution for all of your finishing, laminating, and mounting needs. The Guardian’s intuitive design makes for quick and easy use, maintenance, and cleaning… saving you time on production. Solid, all-steel construction, cold or heat assist models, crowned silicone rollers, upper and lower idler bars, single level nip adjustment, and easy load drop-in supply mandrels with a centering system provide high-quality performance. For more information visit supply55.com, call 734-668-0755, or email sales@supply55.com. INFO# 19
Trim USA’s Perimeter Trim System gives you the ability to quickly, easily, and inexpensively install decorative edge protection around your mounted images. This system eliminates the need for hand cu ers, rulers, and markers, with li le training needed to operate. Giving your mounted images a polished finish that adds value and distinguishes your work. The high impact ABS plastic extrusions will not shrink or warp, which means that your work will last. Give Trim USA a call at 800-642-0959 or email sales@trimusa.com. INFO# 20
be used for home décor applications such as printed curtains, upholstery, and decorative pillows. UV printing on textiles can also provide unique textures and �inishes suitable for interior design elements,” shares Bach.
“Printing with pigment inks on textiles is best for decorative applications. Printing with dyes is recommended for wearable fabrics, garments, or fabrics that will be laundered,” recommends a representative from Jacquard Inkjet Fabric Systems.
Textiles that print well to multiple types of ink are able to do so thanks to speci�ic surface treatments and coatings. Proprietary technologies per fabric manufacturer are often seen here.
Manufacturers conduct extensive research to optimize fabric treatments for compatibility across different ink sets. However, while speci�ic formulations and processes may differ between manufacturers, Bach says “the fundamental principles of surface treatment, ink compatibility, and fabric composition are generally standardized. Manufacturers differentiate themselves through innovations in coatings, environmental sustainability, and performance characteristics tailored to market needs.”
Each manufacturer develops proprietary coatings, agrees the Jacquard representative. “There are many textiles prepared for pigment printing. Textiles prepared for dye printing are rarer and Jacquard is considered a trailblazer and best of class in this area.”
Jacquard specializes in treating textiles for direct printing with pigment inks and various types of dye inks. Its Fabrisign coating allows for maximum color vibrancy and detail when printing with pigment inks. Procoat coating allows for maximum color vibrancy, detail, and washfastness when printing with acid dyes. Reactive coating allows for maximum color vibrancy, detail, and washfastness when printing with reactive dyes on cotton and other cellulosic fabrics.
“Different ink types have speci�ic requirements regarding absorption and interaction with substrates. Textiles optimized for digital printing are engineered to absorb UV, resin, or sublimation inks without compromising print quality or durability. This compatibility ensures that the ink adheres well to the fabric and resists fading or smudging,” explains Bach.
Aberdeen Fabrics offers a cuttingedge solution with its CleanRTex process, which produces sustainable textiles for digital printing with multiple types of ink, including UV and sublimation. Its textiles are designed to be versatile, catering to a range of applications.
Aurora Specialty Textiles Group, Inc. features the Expressions line, which is compatible with UV, resin, and solvent/eco-solvent printers. The proprietary Expressions coating offers cross-platform compatibility as well as outstanding image quality and color gamut.
Fisher Textiles’ ET 9019 Nirvana BOB is UV and dye-sub printable. Made from 40 percent
post-consumer recycled polyester, it is a blackback fabric designed for soft signage displays. The soft knit fabric features a coated back, which provides a built-in liner for �inished applications.
Jacquard offers a range of different natural and synthetic textiles that are prepared for various types of pigment and dye inks. Jacquard also offers bespoke coating services for textiles provided by the customer, with low minimums.
SENFA’s PEARL ABSOLUTE BLACK and PEARL ABSOLUTE COLOR are compatible with UV, latex, direct sublimation, and transfer inks. These versatile coated products with smooth �inishes deliver premium print results, superb deep, saturated colors with all the necessary �lame retardant certi�ications.
TVF’s 5.2 oz. Eco Prism fabric is a lightweight backlit textile made from recycled yarns and comes �inished in a light-diffusing, inkjetcompatible coating that eliminates pinholes and hot spots. A polyester fabric, it is compatible with ecosolvent, resin, and UV inks.
Ultra�lex Systems, Inc.’s VorTex T line is composed of fabrics designed for dye transfer, resin, and UV processes. The VorTex S line is designed for solvent, eco-solvent, UV, and resin printers. The range of S line products includes both knitted and woven fabrics.
To minimize inventory in regards to rolls of fabric consider a substrate engineered for multiple ink sets. D
isplay and point of purchase (POP) applications run the gamut from end caps and shelf talkers made up from digitally printed rigid substrates to pressure-sensitive, adhesive-backed floor graphics and sublimated fabric used in silicone edge graphic (SEG) frames.
by Melissa Donovan
The display and POP segment of the graphic arts has changed significantly over the years. Runs were large, produced via analog technology, and as digital printing advanced so did display and POP, catering to demand for short-run, variable products for highly targeted markets.
Applications that fall under display and POP change as new printing technologies are introduced. The constant is retail and other clients choosing digital printing to convey their brand and marketing message in a consistent, quality fashion.
“By printing display signage, businesses achieve vibrant output efficiently, meeting client demands of specific brand color matching, requested materials, and fast turnaround times. This adaptability ensures that printed display signage remains a powerful tool in retail environments,” suggests David Lopez, product manager, professional imaging, Epson.
Traditionally, “POP signage was completely printed and in very basic fashion, providing function over form, with extremely low-cost materials and production value,” explains the product management team from Mutoh America, Inc.
“POP and retail display were some of the first commercial applications for wide format digital printing, reaching back to the early 2000s. Backlit and reflective posters decorated retail stores to showcase storewide sales, or hail the incoming Shown) The Mimaki CFX Series flatbed cutting plotters address a range of applications like POP displays.
fashion seasons. In the early days, the technology was primarily aqueous or electrostatic inkjet based, along with digital photo imaging for continuous-tone applications such as promoting cosmetics,” explains Timothy Mitchell, senior manager, customer experience, Mimaki USA, Inc.
Solvent and later eco-solvent evolved, offering outdoor graphics without the need for lamination. “This gave print service providers (PSPs) more flexibility in delivering products to their customers using only one technology. UV then came along and added even more versatility, followed by UV LED, which further broadened the application portfolio,” states Mitchell.
In terms of print technologies, Mitchell believes “nothing supports the breadth and depth of application variability like UV LED printers arrayed with white and clear inks; PSPs can print almost
anything imaginable and on nearly any substrate with excellent quality and outdoor durability.”
According to Mike Syverson, textile manager - NA, Durst Image Technology, “the first digital prints were mostly produced on vinyl and rigid substrates such as pressure-sensitive vinyl, expanded PVC, and styrene. There is a large part of the market that is still produced this way in addition to card stock, corrugate, and dye-sublimated (dye-sub) fabric displays, primarily using SEG.”
SEG is one display and POP application really taking off. Syverson says about ten to 15 years ago it grew in popularity primarily in Europe. PSPs and their customers were looking for less expensive ways to produce and ship products.
“The trade show and event space drove much of the initial SEG conversion. The display and POP segments saw the significant savings from the event space and
converted many traditional applications to SEG. The NA market followed several years after. Many retailers, large and small, are moving to fabric graphics for the same reasons,” adds Syverson.
Lopez says that “today, display signage is everywhere. At retail locations, it includes everything from end caps, retail check out lines, themed cardboard pop up displays, hanging graphics, and floor graphics—all designed to inform and influence purchase habits.”
Modern POP is more creative than ever before. “It engages customers by including the integration of concepts like advanced floor graphics—people are looking down at their phones and not eye level anymore. The latest trend is utilizing digital technology to drive customer engagement and make the experience interactive,” shares the team at Mutoh.
“In recent years, signage trends have evolved, stemming from a deeper understanding of the psychology of buyers and human interactions. Numerous studies now underscore how specific colors, human behavior, and natural habits impact purchasing decisions. This insight directly influences marketing campaigns and dictates design choices in regard to the size, color, design, wording, and location of the sign or POP display,” explains Lopez.
Shelf talkers, end caps, floor graphics, and SEG displays are some of the more notable applications found in display and POP.
“Standard banners and print/cut graphics—such as for use in shelf talkers—continue to show growth in the digital printing space because of their demand and durability with ink technologies such as solvent,” notes Mitchell.
One example that Mutoh’s product managers have noticed involves end caps. “End caps incorporate very complex printed designs that reflect either the brand mascot, packaging, or company mission.”
Floor graphics, which gained popularity during the COVID-19 pandemic, are making a comeback due to their versatility, according to Lopez. “Floor graphics are affordable, offer high visibility and attention due to their unexpected placement, are an effective use of space, and are relatively easy to install and remove.”
SEG displays are another application trend in display and POP. Syverson lists several drivers for this—the first being cost. “Once the frames are installed, graphics can easily be installed by employees of the retailer versus bringing in outside installers, saving labor costs. Second, shipping finished fabric graphics is significantly less expensive than other print technologies. Fabric graphics can be folded and shipped via standard carriers. Vinyl or rigid graphics are usually rolled or palletized and shipped freight.”
“Soft signage continues to show year-to-year growth in overall demand and functionality. Many retail spaces appreciate the ease of installation and handling that soft signage provides. And shipping costs are significantly less with no damage caused by delivery. This is followed by increased awareness of backlit applications that can easily be achieved with solvent, UV, and sublimation transfer ink technologies,” agrees Mitchell.
SEG displays are also a popular display and POP application because they convey a high-quality look and feel. “Lead times are getting shorter, and quality requirements are increasing all the time. The systems in place today must be able to produce high quality, high speed, and reliable output with lower operational costs,” says Syverson.
“Finally, several take-back programs are being put together to recycle or re-use dye-sub fabrics, which is becoming another key driver for many retailers,” explains Syverson.
Found across all applications is the use of bright colors, another trend Lopez notices more of. “Digital printing allows professional signage printers to use a mix-color process to achieve vivid and fluorescent colors that were nearly impossible to create with previous printing technologies. The combination of the incredible color gamut and the fast print speeds of digital printers enable the creation of vivid, eye-catching displays that quickly meet fast turnaround times.”
Display and POP applications are influenced by a number of factors like consumable pricing and shipping/ordering lead times. In response, PSPs need to work with efficient technology.
Big box retail stores in particular feel the pinch in pricing. “For industries like grocery, home improvement, or department stores, the requirement of pricing and adequate lead time is paramount,” explains the product management team at Mutoh.
On the flip side, Mutoh’s product managers believe that high fashion and luxury retail stores don’t care nearly as much about pricing. Instead they demand high quality, sustainability, and repeatable results.
End users from all backgrounds “are changing graphics more frequently to match up with their programs. This requires flexibility on the PSP side. The key is having quick turnaround, easy installation, and reduced overall cost, of which shipping can be a large component,” admits Syverson.
Speed is part of what Lopez refers to as the “Amazon Effect,” which has set a new standard for rapid delivery. “It pushes printers to meet tighter deadlines and heightened customer expectations. Customers now expect quick turnaround times, even for custom
and complex projects. This trend has set a precedent across the display signage and digital printing industries, making it important for printers to adopt efficient workflows and integrate advanced digital printing technologies to meet these expectations.”
“Costs and lead times will always be an issue no matter the industry. We see PSPs pivoting to improve workflow and maximize consumable usage. Automation, artificial intelligence (AI) assist, and efficiency can offset headwinds from shipping and consumable price fluctuations. Businesses should always be looking for process efficiency and the wide format printing industry is no different. As AI advances it will be a source of predictable workflows where algorithms decide outcomes rather than opinions with the goal being reduced timelines and errors, and increased volume and accuracy,” suggests Mitchell.
Roll, flatbed, and hybrid wide format printers influence application demand, especially in the display and POP space.
In the roll-to-roll segment, the capabilities of dye-sub roll devices in particular drive the demand for SEG displays. “High-traffic areas like airport restaurants and retail are almost exclusively moving to either SEG or digital signage,”
says the product management team at Mutoh.
“SEG implementations have increased in the past five years. We’ve seen many large retailers change some or all of their interior POP and display graphics to fabric, mostly produced with dye-sub on systems such as the Durst P5 TEX iSUB with inline sublimation,” agrees Syverson.
With dedicated flatbed printers, embellishments are particularly relevant. Mutoh’s UV LED technology allows for adding 2.5-inch dimensional texture, spot-lenticular with its Lenticular 2.0 system, and also create graphics with different gloss finishes within the same printing pass.
“UV LED flatbed technology continues to present demand in the signage space, and object decoration is rapidly being adopted due to the virtually limitless applications and easy integration into many print environments. Whether a customer is an existing PSP or just starting out, the mature print technology currently available provides opportunities for success in every application type and niche,” adds Mitchell.
“Print shops that invest in UV or UV flatbed printers can now print on almost anything, including wood, glass, and plastic. Without a UV flatbed printing to these mediums, there is a more complicated process and elongated turnaround times for customers. The introduction of UV flatbed printing technology helps simplify these processes and broadens the scope of display signage applications,
transitioning from conventional flat signage to innovative, custom designs,” agrees Lopez.
Hybrid—flatbed and roll in one—printers are also relevant in display and POP. One example, Mutoh’s ValueJet MH series. These multi-purpose devices adhere to uncoated materials. “This allows advertisers to proof on the final intended material instead of relying on coated stock—saving time and cost,” explains product managers from Mutoh.
Current display and POP application trends encourage interaction with the end user; as well as shorter term promotions to keep up with the fast pace of today’s limited marketing campaigns. This will continue into the foreseeable future.
“The trend is sharply moving to digital print as the cost of displays continues to decrease; there is the advantage of interactivity with the consumer, and the ability to personalize and quickly modify the graphics as needed,” shares the product marketing team at Mutoh.
Lopez agrees that interactivity will be prevalent for days, months, and years to come. “Display signage trends will continue to focus on attention-grabbing techniques such as innovative signage, floor graphics, and interactive displays. The integration of screens into printed materials is becoming increasingly popular, offering dynamic and engaging experiences that capture audience attention. This trend reflects a broader shift towards combining physical and
digital elements to create more immersive and interactive marketing campaigns.”
“Display and POP markets are always evolving. End clients are looking for new ways to drive more business and push PSPs to increase efficiencies and innovate new products,” admits Syverson.
PSPs utilize new products with improved speed, ink, and media compatibility in response. Mitchell believes this is why “we are seeing a trend of smaller to medium producers taking on larger jobs that may have traditionally been outsourced. This trend has opened a market for these smaller providers to bid on jobs at museums, airports, and hospitals. A small but highly efficient print provider can accomplish far more today than a decade ago with meaningful advances in both productivity and versatility.”
Today’s display and POP applications benefit from updated printing technology. PSPs can leverage their hardware to take advantage of this.
“Modern digital printers now have the technology to provide display signage customers with brighter colors, accurate color matching, increased media compatibility, and faster turnaround times from project order to completion and installation,” adds Lopez.
Learn more about display and POP applications in our webinar on the same topic. To access this broadcast visit digitaloutput.net/ webinars. D
by Graphic Whizard USA, Inc.
Chris has been in the printing industry for 38 years, spending the first 15 as a technician then transitioning to sales. He has been with Graphic Whizard USA, Inc. (GW) for just over 16 and a half years.
How do you connect with customers?
I connect with customers through various means; social media like LinkedIn, leads through our website, customer visits either in my territory or while supporting my dealer managers in theirs. My greatest and most impactful connections are opportunities when I can demonstrate our machine capabilities in front of business owners who would benefit from our solutions. For example, meeting up with the GW Roadshow trailer when it is out visiting shops; seeing the customer’s face when a fully equipped showroom rolls up to their door, they realize they can push a few buttons and discover how we can help increase sales and lower costs.
Do you feel it is important to do trade shows?
Absolutely. Trade shows give us the opportunity to do live demonstrations with our solutions as well as learn about our customers’ requirements. I never start talking about machines without learning about the customer’s current business practices. Questions like “how do you do it now?” can lead to a very productive demonstration. Shows also give us the opportunity to introduce new equipment and take in feedback. At Printing United 2024, we took our biggest booth space ever and introduced nine new pieces of equipment. It is the most expedient way to demonstrate new machines to a large audience that includes many of our dealers as well as end users.
GW offers such a broad range of machinery; how do you know where to invest in equipment?
Ask the right questions and listen to the answers, for example asking, “how often do you have a need for a
particular task?”, typically guides us as a company to wonder whether others would need an in-house solution and what equipment may be required, or could be developed, to resolve pain points and help increase our customers’ productivity.
All machines GW launched at Printing United this year were sourced or developed in response to customer demand. They included two new guillotine cutters and three new perfect binders as well as a small footprint laminator, which is causing buzz. We have a new inline multi-folder for the 8336SCCM, which can perform multiple jobs at once and function as an outfeed when the job does not require folding. Finally, in partnership with POA GW’s West Coast dealer we showcased the PT 8336C SCC Multi inline with a Ricoh C5300 digital press. POA placed the first 8336C SCC in North America earlier this year. All these machines are part of our company’s commitment to continually develop our product line to provide the best possible print finishing solutions for our customers.
Visit graphicwhizard.com to learn more about the company’s newest product releases. D
148 Photo Tex Group Inc. Photo Tex (EXS) High Tack
phototexgroup.com
by Cassandra Balentine
here is a growing interest in UV liquid coating for the purpose of protecting and finishing wide format roll-to- roll graphics like wallcoverings, decals, banners, posters, and fleet wraps.
While the use of UV liquid coating is popular in the narrow format space, recent technology introductions have fostered intrigue in its use for large format graphics finishing.
“Narrow web UV coating has been around a long time. But, large format UV coating is starting to make big strides,” says Syd Northup, VP,
sales, digital U.S., Marabu North America. “Large sign and graphic shops are starting to see the benefits
of coating to protect graphics quickly and efficiently. Most importantly, the amount of labor and time to process/coat a job versus film lamination is paramount.”
During the initial years of UV LED in print, Brian Buisker, president, and Hayes Holzhauer, partner, Advanced Greig Laminators, Inc. (AGL), point out that narrow format adopted the technology first due to the smaller width requirements. “As technology advanced, it allowed for wider UV LED lamps to be designed as well as a reduction in cost, making it a viable option in wide format.”
An advantage to UV is the ability to print an image and immediately send it for finishing. The coated image cures in seconds. “This process speeds up any production environment that needs to get product out the door quickly—i.e real estate signs, outdoor signage, banners, etc.,” comments Northup.
Buisker and Holzhauer note that UV LED curing has been in wide format printers for years. “AGL is introducing this technology for the first time to the wide format coating/laminating industry.”
They point to numerous benefits of UV LED curing for wide format
coating and laminating, including power savings, reduced emissions and replacement costs, a smaller footprint, and instant on/off capabilities.
Substantial power savings are possible with UV LED compared to traditional UV mercury arc lamps, which Buisker and Holzhauer say use 70 percent more electrical power to operate than low heat, low energy UV LED technologies.
UV LED lamps perform at 50 percent lower CO2 emissions. “The lamps generate no ozone and offer the elimination of toxic mercury. No ventilation is required with UV LED,” add Buisker and Holzhauer. Further, instant on/off of UV LED allows for more efficient operations and cost savings.
In terms of replacement costs, Buisker and Holzhauer note that typical UV arc lamps need to be replaced every 1,500 hours or sooner while UV LED lamps last for around 60,000 hours when maintained correctly. “UV LED technology avoids these replacement costs and eliminates the hazardous mercury. This can amount to $32,000 to $35,000 in savings per year.”
A smaller footprint is standard with AGL’s SheerKote UV62 machine, which uses approximately 64 square feet of space while UV
arc machines take upwards of 160 square feet of space, comment Buisker and Holzhauer.
Of course, there are challenges to consider. “One of the biggest challenges is the cost of a UV coater. Unlike Marabu’s low-cost StarLam liquid laminator for waterbased coating, the cost of a UV coater can range anywhere from $80,000 to $200,000,” points out Northrup.
Among solutions for wide format, rollfed liquid lamination solutions is the AGL SheerKote UV62 liquid coater, which is designed specifically for rollto-roll liquid coating on an industrial level. It is the first model in AGL’s SheerKote line of UV LED liquid coating equipment.
With conventional UV arc curing known to produce ozone, which is a hazard for employees and requires costly ventilation equipment, the AGL SheerKote UV62
offers an attractive proposition. “The UV LED curing technology in the UV62 does not create any ozone or volatile organic compounds—so no costly ventilation is required,” explain Buisker and Holzhauer.
technology, which provides a superior coat finish. “The meyer bar allows for quick setup and breakdown of the machine, saving valuable time and keeping a cleaner working environment,” note Buisker and Holzhauer.
The water-cooled UV LED system in the AGL SheerKote UV62 is also of note, as it increases the substrate temperature by just ten to 25 degrees Fahrenheit— compared to 70 to 90 degrees Fahrenheit with UV arc—allowing easier coating of temperature sensitive materials.
Further, the AGL SheerKote UV62 utilizes meyer rod coating
AGL also formulated the KoteRite line of liquid coatings for the SheerKote line of liquid coaters. They offer universal ink compatibility, which means excellent adhesion, flexibility, and protection over latex, UV, and solvent inks. Gloss, satin, and matte finishes are available in a variety of grades to fit your specific application.
Buisker and Holzhauer feel that this technology will open the door for smaller wide format shops to incorporate a SheerKote machine due to its smaller footprint and allow them to realize the cost savings of $0.03 to $0.05 per square foot coating costs rather than $0.30 to $0.50 per square foot costs for dry lamination film.
Marabu also offers a UV-curable liquid coating, Marashield, which is applied with UV roller coating machines. The company believes this technology offers “unbeatable advantages and unparalleled versatility when compared to traditional film lamination as
Marashield coatings are not only less expensive than laminating films, they also improve efficiency in production.”
Marashield is multi-purpose and can be used as a primer, finisher, and for protection. As a primer, Marashield coatings create an evenly applied primer as a bonding layer for inks on surfaces that are typically challenging to adhere to properly, such as glass.
“UV stability is our biggest benefit,” states Northup. He says most UVcurable liquid coatings do not have UV inhibitors to protect against UV rays. MaraShield offers high resistance to abrasion, chemicals, UV rays, and graffiti. The company points out that Marashield coatings have passed numerous tests ensuring maximum protection of the end product.
Northup says Marashield is seen as a smart alternative to film lamination cost, in addition to the protection presented as well as consistent quality.
Further, Northup feels the competitive advantage of an eye-catching professional look cannot be underestimated. “With Marashield, the best and most professional look is achievable each time you coat.”
While liquid coating is generating attention, film and heat-assist
1) Marabu offers a UV-curable liquid coating, Marashield, which is applied with UV roller coating machines. 2) Mimaki offers the LA-160W heatassisted laminator, a 62-inch wide device designed to improve laminate film adhesion, particularly to surfaces printed with UV LED ink, and reduces the potential for the silvering effect created by pressure-sensitive laminates.
lamination is a strong player in wide format finishing.
Sam Crosby, dealer manager, Graphic Finishing Partners, LLC, feels that the company’s roll film options offer benefits that liquid laminating cannot. This includes superior abrasion resistance, adding body to assist with the installation process—especially as it pertains to vehicle graphics, more affordable equipment options, and the ability to “finish on demand” compared to the traditional liquid process.
Among available film lamination equipment, Mimaki USA, Inc. offers the LA-160W heat-assisted laminator, a 62-inch wide device that Timothy Mitchell, senior manager, customer experience, Mimaki, says improves laminate
film adhesion, particularly to surfaces printed with UV LED ink, and reduces the potential for the silvering effect created by pressure-sensitive laminates.
Additionally, Mimaki Vision Laminate 310 (Gloss) film offers fine finishing with a glossy feel while maintaining the color brightness of the print. “This high-quality, heat-assisted overlaminate is also a cost-effective alternative to cold laminating films,” shares Mitchell.
While film-based lamination is well established as a preferred finishing method for wide for-
mat graphics, UV LED curing is an emerging technology for wide format finishing, particularly for roll-to-roll operations. Applications like wallcoverings, decals, banners, posters, and fleet graphics benefit from potential power savings, reduced emissions and replacement costs, smaller footprint, and instant curing. D
dling accelerates a production workflow. Today’s router and cutter manufacturers targeting the wide format graphic arts continue to introduce advancements that relate to automated feeding and stacking as well as robotic material handling.
While the concept is nothing new, notable improvements to feeders and stackers help reduce downtime and enable faster turnaround times.
The automation of board handling is gaining popularity in the digital print market. Keith Verkem, national sales manager and senior product, manager, Colex Finishing, Inc., feels that this because it requires less operator intervention and provides increased productivity.
by Cassandra Balentine
production more efficient and profitable, and material handling is a big part of that.
“No matter whether in printing or cutting/ finishing, if manpower, or the lack thereof, is a consideration, or if there is anything else impeding the flow of materials that keeps your printer—or cutter—from operating as close to non-stop as possible, print service providers (PSPs) are not getting as
Beatrice Drury, communications manager, Zund America, Inc., agrees, pointing out that automation is the driving force in making every aspect of digital graphics
much return on investment (ROI) as they should from their digital production equipment.”
Drury adds that naturally, the faster the printer, the more likely it will create bottlenecks downstream, which makes implementing efficient, reliable material handling automation even more of a must, especially when it can be done without having to hire additional staff.
“The demand for automation is to maximize productivity for the end users. Automation reduces costs and increases output, especially with finishing from the flatbed cutters,” adds Gary Buck, VP, sales and marketing, Summa.
As businesses look to the future they are focused on automation. “One of the primary goals of automation is to increase productivity, which is obviously one of the major pain points converters experience today. Our extensive
testing has shown that a robotic material handling solution with dual table setup can in theory increase productivity by as much as up to four times, dependent on other factors,” offers Nimil David, product manager, automation and robotics, Kongsberg Precision Cutting Systems (PCS). “Alongside that increased throughput, quality is also of paramount importance—any automation should ensure that the handling of the thousandth sheet is the same as the first, delivering consistency as well as speed.”
Streamlined integrated workflows are key. In July 2024, Canon Solutions America announced the availability of a fully automated print-to-pallet production workflow with Texas series flatbed printers manufactured by DigiTech and Kongsberg PCS cutters.
“These automated workflows integrate printers and routers/ cutters with conveyors and other material handling automation to enable seamless transitions from print to cut to pallet,” says a representative from Canon.
Board handing advancements are particularly useful for PSPs that operate routers/cutters in house for graphics and signage.
With the improved efficiency and productivity these options can bring, Buck says the result is less manual handling of the substrate.
Verkem agrees, noting that these advancements are useful for PSPs looking to minimize operator handing of media.
For example, Kongsberg PCS’ automated Feeder & Stacker and Robotic Material Handler are designed and developed specifically to deliver significant benefits to any converter. “The removal of any manual handling between steps not only increases speed and accuracy of locating and removing materials, but also eliminates any chance of human error that can lead to damage and costly errors,” comments David.
“No matter the application— whether it’s for signage, graphics, displays, or packaging—once a
PSP operating finishing equipment has the highspeed printing capacity and the order volume that demands near constant equipment availability, automated material handling becomes an indispensable component of an efficient production workflow. This is especially true when the board handling hardware is combined with machinecontrol and workflow software that allows for processing large amounts of small jobs—another type of ‘high volume’ production—without having to stop the system to retrieve files or manually change the setup,” shares Drury.
Many board handling advancements target environments of high productivity. Therefore, it is recommended that smaller PSPs weigh the considerations throughly before making an investment decision.
Buck points out that a high level of finishing automation may not be as important to smaller shops unless they have a specific program where high-quantity runs would require the automation.
For smaller sign shops, Drury feels that it does make sense to first explore other options to maximize cutting/finishing efficiency that may require less of an investment. “There are various productivity features and levels of automation available with Zünd cutting systems, including
a tandem setup and workflow, which is a manual but extremely efficient solution involving the cutter operating on one half of the machine while loading/unloading occurs on the other.”
However, Drury is quick to point out that when considering an initial investment in digital cutting/finishing, it is important for PSPs to insist on modularity and upgradability. “Even if their present order volume does not demand the level of automation that automated or robotic board handling systems offer, they need to keep in mind their needs may change and opt for equipment that can easily accommodate future expansion.”
Verkem adds that as long as small sign shops have space for board loaders it minimizes labor costs and minimizes turnaround time.
“There is a place for automation in both situations,” states David, noting that ROI is a hugely important consideration. “That’s why we always look at every project on its own merits, leading each customer through a comprehensive discovery phase with our team of experts.”
For Kongsberg PCS, its team and the customer use this discovery phase to jointly examine all the specifications and parameters and ensure that automation is the right solution to maximize throughput
and achieve the best ROI. “We’re not just selling a machine, we’re helping to develop the whole process. We look at whether there are any limitations in the facility, either in the immediate environment like the floor or height of the ceiling, or whether the location has the flexibility to make requisite changes to accommodate a moving arm of a Robotic Material Handler,” says David.
“We don’t just deliver a robot and say, ‘off you go.’ We help map out the layout of the customer’s whole production room or shop floor, down to the location of the electrical cabinet, to ensure they can accommodate the robotic cell,” explains David. “As automation
and robotics represent a significant investment, this testing and planning phase allow the customer to have 100 percent confidence in the setup. They need to know it is going to deliver the productivity gains they are investing in achieving. Our insistence on this phase underlines our own confidence in the benefits of the automated system—and it delivering just that.”
When making an investment, it’s all about the ROI. However, this is often a complicated equation. Verkem feels that especially for large-volume jobs, estimated breakeven points and ROIs can be justified when it comes to automated board handling.
“Volume, employee cost, consistency of production, and automation cost all come in to play,” shares Buck.
Drury believes there are far too many variables involved to determine a general breakeven point, both on the part of the PSP as well as their particular production environment and the type of automated workflow/material handling they are considering.
“From simple sheet feeder to fully automated, robotic loading/ stacking, picking/placing, etc.,
2) Among recent innovations in its digital flatbed cutting line, Zünd offers the Q-Line with board handling system—BHS180 and UNDERCAM, which enables efficient order processing, whether custom or longer runs, and requires a seamless and transparent flow of data.
there are many options designed for meeting specific needs. One important consideration is weighing the cost and returns on utilizing manpower vs. implementing workflow automation. Using automation for menial, repetitive tasks can result in significant cost savings while at the same time freeing up staff to perform more complex, meaningful tasks that by definition also add more value.”
A range of rigid substrates are well suited for automated board handling for wide format routers and cutters.
Buck says coroplast, PVC, ACM, foamcore, and pressure-sensitive adhesive vinyl are materials
he most often sees as needing automation, both in terms of feed input and output (stacking).
“It is important to have a printer and automation that can handle a variety of different rigid substrates in both material and size,” notes the Canon represenative.
Drury admits that there are few limitations to handling most commonly used graphics substrates. “Excessive weight is probably the main issue when it comes to thick sheets of heavy, dense materials such as aluminum and acrylic. On the other hand, knife cutting these types of materials is not an option anyway. Processing these heavy-duty substrates automatically involves routing and, in conjunction with an automated feeding/advancing system, processing the materials directly on the conveyor belt. While not inherently a problem, this kind of setup will inevitably shorten the lifespan of the belt used for advancing the material into and out of the active cutting area.”
David explains that one of the most advanced automated sheet handling solutions for large format digital finishing, the Kongsberg Feeder & Stacker, has a stack height of 36 inches and quick automatic load cycles. “This makes it the optimal solution for short-run production, able to handle sheet sizes of up to 126x63 inches on all typical packaging and display materials including single-, double-, and triple-wall corrugated; display carton and board; corrugated plastic; fluted core board, and honeycomb board.”
Further, the optional underside camera scans the sheet from below—the print side—and automatically locates the registration marks, barcodes, and the corner of the sheet, which David estimates saves between 20 to 30 minutes per set up. Processing a stack height of 915 millimeters means fewer pallet changes and continuous handling of materials.
Automated sheet feeding and stacking provides a seamless way to increase productivity, eliminating operator intervention and bottlenecks associated with manual material loading. “Enabling this greater unattended operation serves to not only speed up shortrun production but also remove many of the human errors that can create further delays and generate significant waste,” concludes David. D
