DPS May 2026

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MAY2026

DIGITAL PUBLISHING SOLUTIONS

DIGITAL PRINT, PACKAGING, AND PUBLISHING

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TECHNOLOGIES THAT SUPPORT BOOKS ON DEMAND

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Editor’s Letter.....................................................................................4 Leveling Up

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News Beat..........................................................................................6 Current Industry News Finishing..............................................................................................9 High Speed, High Bond Best Practices................................................................................. 12 Media that Meets the Mark Best Practices................................................................................. 16 Cleaner Printing Advertiser Index............................................................................. 18

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Companies Mentioned................................................................. 18

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On the cover: Output from the HP Indigo 120K Digital Press was highlighted at the recent Dscoop Rockies Edge event in CO this March. See page 20.

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dpsmagazine.com Volume 28, Number 3 • ISSN: 1529-2320

Leveling Up In today’s divisive economy print providers must level up while trying to stay above water. Everything is changing and evolving at warp speed and those that don’t adapt are left behind. This issue is all about finding ways to improve productivity, profitability, and/or appeal.

For example, the publishing industry knows too well the move to shorter, more variable runs. Thankfully, print and finishing providers focus on supporting book manufacturing with automation. Book Smart highlights recent advancements in both print engines and finishing systems that enable near touch-less operation.

Everything is changing and evolving at warp speed and those that don’t adapt are left behind.

Additionally, tune into our recent webinar on this topic, featuring expert insight from Muller Martini/Hunkeler, Standard Finishing, and Tecnau, available now at dpsmagazine.com/webinars.

Another area with increased emphasis is sustainability. Cleaner Printing discusses the initiatives implemented on the ink and toner side of the business, and Media that Meets the Mark tackles substrate sustainability.

Moving over to packaging, we put the spotlight on thermal lamination in the digitally printed flexible packaging space. Solving key challenges like cure time and compliance concerns, the process takes into consideration heat-sensitive media and adhesion issues common to digitally printed output. Check out High Speed, High Bond for more perspective on the topic.

As always visit us online at dpsmagazine.com for web-exclusive articles, industry news, issue archives, webinars, and more!

Cheers,

EDITOR IN CHIEF Thomas Tetreault 978-921-7850 EDITOR Cassandra Balentine cbalentine@rockportpubs.com ASSOCIATE EDITOR Melissa Donovan mdonovan@rockportpubs.com ART DIRECTOR Sarah M. White swhite@rockportpubs.com WEB EDITOR Melissa Mueller CONTRIBUTORS Marco Boer, Kemal Carr, Richard Huff ADVERTISING SALES PUBLISHER Thomas Tetreault 300 Newburyport Turnpike, Ste. 11 Rowley, MA 01969 Ph 978-921-7850 x110 • Fx 978-921-7870 edit@rockportpubs.com SALES Amanda Doyon Ph 978-921-7850 x170 • Fx 978-921-7870 adoyon@rockportpubs.com Subscribe online at dpsmagazine.com

CORPORATE & PUBLISHING OFFICE 300 Newburyport Turnpike, Ste. 11 Rowley, MA 01969 ROCKPORT CUSTOM PUBLISHING, LLC CHAIRMAN Jeffrey Jensen PRESIDENT & CEO Thomas Tetreault CONTROLLER Missy Tyler

Cassandra Balentine, editor cbalentine@rockportpubs.com

Digital Publishing Solutions is published by Rockport Custom Publishing, LLC. Please send change of address forms to: 300 Newburyport Turnpike, Ste. 11, Rowley, MA 01969. © Rockport Custom Publishing, LLC 2026. Reproduction by any means of the whole or part of Digital Publishing Solutions without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply our endorsement.

Subscription Rates: U.S. $41.65 per year, seven issues; single copies: $5.95, Canada and Mexico: $52.22 (U.S.D.), Other international subscriptions: $71.05 (U.S.D.) 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, DPS Magazine, 300 Newburyport Turnpike, Ste. 11, Rowley, MA 01969. We cannot be responsible for unsolicited product samples.

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STAY ON TOP OF THE LATEST INDUSTRY BUZZ. We’ve compiled news releases from the industry to keep you up to speed with the most recent stirrings in the digital print, packaging, and publishing arena. Check out eleventh-hour updates in each print issue and daily online at dpsmagazine.com. For FREE information about products and services visit dpsmagdirect.com.

Konica Minolta and TROY Group Unveil the TROY AccurioPrint 2100 MICR Konica Minolta Business Solutions U.S.A., Inc., in partnership with TROY Group, release the TROY AccurioPrint 2100 MICR high-speed monochrome production printer. Built for entry-level production check printing environments, this new model offers a secure and scalable solution for organizations seeking to centralize check printing without compromising compliance or performance. The launch marks a strategic addition to Konica Minolta's TROY production MICR lineup.

The TROY AccurioPrint 2100 MICR is equipped with TROY's patented MICR Toner Secure anti-fraud toner. This advanced

technology is designed to meet stringent banking standards and provides unmatched protection against check fraud by bleeding red when tampering or check washing is detected. Delivering 100 A4 pages per minute and supporting a monthly peak volume of up to 2.25 million pages, the printer is ideal for financial institutions, service bureaus, governments, and enterprises with high-volume secure printing needs.

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Xerox Debuts Production Presses and Workflow Software This February, Xerox hosted The Future of Xerox Production Print event at the Xerox Innovation Centre in Uxbridge.

It featured hands-on demonstrations, technology previews, and executive briefings designed to accelerate growth in the production print market.​ The event marked the global debut of several new technologies, including the new Xerox Proficio PX300, Xerox Proficio PX500, Xerox IJP900 Inkjet Press, Xerox PrimeLink C9200 Series, Xerox FreeFlow Vision Connect Software, as well as new support for the Xerox IJP900 Inkjet Press.

Together, these digital presses and workflow software tools are designed to help expand opportunities for print providers across high-quality color, high-volume inkjet, and automated production.

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finishing

High Speed/ High Bond

Thermal Finishing for Flexible Packaging

By Cassandra Balentine 0-----------------------------------------

Thermal lamination uses heat to fuse a layer of protective film onto a paper or plastic substrate. It is commonly used to protect printed surfaces from damage in storage and transit, or to give product packaging moisture-resistant qualities.

This finishing technique plays an evolving role in digitally printed fiexible packaging.

Additionally, thermal lamination uses Addressing Challenges According to Ryan Chai, category lead, Label and Packaging, Nobelus, the heat and pressure, so there is no solvent Whether it is toner-based, HP Indigo, or primary benefit of thermal lamination chemistry involved in the bond itself. a high-speed inkjet press, digital print­ for digitally printed packaging is that "That removes a whole category of com­ ing produces a surface that behaves dif­ it has no wet adhesive cure time. "You pliance risk, especially as regulators and ferently than flexography or offset. For laminate, you finish, and you're done." brand owners get more aggressive about instance, ink laydown is thinner, the sur­ "Thermal lamination requires zero what they'll accept in food-contact pack­ face energy varies by substrate, and sen­ curing time, allowing for immediate aging," comments Chai. sitivity to the heat and pressure involved "Because the process is entirely dry, it in lamination is possible, explains Chai. converting, cutting, and finishing and fu­ A laminate engineered for digital ture inline solutions," agrees Joan Marc eliminates the risk of chemical migration Taboas, CEO Enprom Solutions - ABG and residual odors, making it the safest with appropriate adhesion chemistries Girona (ABG International Group). and most compliant choice for food and and processing temperatures is going to For a converter running short-run pharmaceutical packaging," adds Taboas. perform more consistently than a gendigital jobs with fast turn­ eral-purpose film pulled from a commodity catalog and put on a arounds, that can be the differThe challenge is that digital toners and ence between making a deal or digital press. inks create a surface that conventional not. "This is compared to sol1. Nobelus built its fiexible packaging port­ vent- or water-based adhesive laminate adhesion wasn't designed for. folio around the needs of converters that lamination where you're waiting - Ryan Chai, category lead, want to move faster and do more in house. for cure windows before you can Label and Packaging, Nobelus 2. Karlville is ah HP Indigo Pack Ready cut, slit, and deliver," adds Chai. lamination provider.

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Adhesion in digital printing is often more complex than conventional printing, and Chai suggests that the topic doesn’t get enough attention in conversation.

“The challenge is that digital toners and inks—particularly electrophotographic toners like HP Indigo ElectroInk—create a surface that conventional laminate adhesion wasn’t designed for.

The toner layer sits on top of the substrate and can act as a release layer if the laminate chemistry isn’t right. You can pass a basic adhesion test and still see delamination in the field when exposed to cold temperature, moisture, or stress,” explains Chai.

To address this issue, Nobelus starts with film selection and adhesive chemistry matched to the print process. “For converters running HP Indigo equipment, that means a thermal laminate with an EVA or co-polymer adhesive formulated to bond effectively through the toner layer, not just to the substrate beneath it. For inkjet, you’re dealing with different ink chemistries and sometimes primer coatings that change the surface profile entirely,” he adds.

Beyond that, process parameters matter—nip pressure, temperature, and line speed all interact with the printed surface in ways that are different from an unprinted substrate.

Chai explains that part of what Nobelus does is “work with converters to dial those parameters in for their specific press and substrate combination rather than handing them a spec sheet and walking away.”

Nobelus has built its flexible packaging portfolio around the needs of converters who want to move faster and do more in house, and thermal lamination is central to that. The Nobelus StrataFlex Thermal Pre-Lams are METPET structures with two functional layers built in—an EVA thermal adhesive layer on one side for lamination and a PE sealant layer on the other for sealing. “When you pair these pre-lams with a reverse-printed film, you significantly cut down on material changeovers on your printing press, which is typically your most expensive asset. That’s a real operational win, especially for converters who focus on shorter digital runs,” says Chai.

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Another vendor, ABG International, provides high-performance thermal laminates specifically engineered for the digital printing sector and as part of its strategic ABG FlexPack roadmap, is set to expand its portfolio with a specialized range of pouch-dedicated solutions.

Karville is one more example of digital ready lamination, the company is an HP Indigo Pack Ready Lamination Provider.

This technology is a set of post-print converting solutions for HP Indigo digital presses that provides zero-cure-time lamination, enabling digital converters to print, laminate, and pack on demand for immediate time to market.

Market Adaption Thermal lamination is adapting to manage heat-sensitive substrates.

“This is one of the more active areas of development right now,” admits Chai.

Digital printing has expanded the range of substrates people want to laminate to, including thinner films, sustainable mono-material polyethylene (PE) films, and shrink materials.

Traditional thermal lamination runs at temperatures that can cause dimensional instability or surface distortion in heat-sensitive materials. Adaptations to handle these issues can occur at a couple of levels.

First is adhesive chemistry. “Adhesives with a lower activation temperature can achieve a good bond at temperatures that don’t stress the substrate.

However, this comes with tradeoffs, and you need to be precise about your processing window,” explains Chai.

Second is equipment design. “Modern thermal laminating systems with precise nip temperature control and variablespeed capability, alongside a variety of wrap angles, give converters much more flexibility than older equipment where you were essentially locked into a narrow operating range,” adds Chai.

Additionally there is a move towards mono-material packaging.

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Mono-material is one of the most significant structural shifts Chai has seen since being in this industry. “Brand owners and retailers are under real pressure—both regulatory and consumer driven—to move packaging toward structures that can be recycled through existing infrastructure. Multi-layer laminates that combine PET, BOPP, PE, and aluminum in the same structure are effective as packaging, but they are essentially unrecyclable at scale. That’s not a sustainable position.”

Thermal lamination plays a meaningful role in enabling mono-material structures. For example, Nobelus’ EcoElement PE Thermal Sealants are a direct response to this as they’re designed to function as both the thermal adhesive layer and sealant layer in an all-PE structure. “When you pair them

with a PE print web, you get a fully flexible, heat-sealable package that’s compatible with PE film recycling streams,” exclaims Chai.

As always, there are tradeoffs with new technology. Chai admits that PEbased structures don’t always match the barrier performance or the print clarity of traditional BOPP/PET constructions or the barrier performance of foil.

“The work right now is on closing that gap—better barrier PE films, improved ink adhesion on PE surfaces for digital printing, and structures that can run on existing equipment without requiring a full retooling of the converter’s production line,” he adds.

Thermal lamination offers a way to add functionality with barrier, sealability, and protection to a mono-material print web while supporting the digital value

proposition. According to Chai, this is the key connection between thermal lamination and where the industry is going regarding sustainability.

Adapting to the Times Thermal lamination is ideal for converters running short-run digital jobs with fast turnarounds as it eliminates the need for dry time. The technology also uses heat and pressure as opposed to solvent chemistry, which can complicate compliance and regulations, especially around food and beverage packaging. Current providers adapt to new demands for digitally printed flexible packaging.

For more on the topic of thermal lamination for digital printing in flexible packaging, visit dpsmagazine.com. dps See page 18 for more information.

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Media that Meets the Mark Demand for Sustainable Media Options Grow

By DPS Magazine Staff

Interest in sustainable substrate options continues to grow within the print industry as providers and customers prioritize eco-friendliness and responsibility to the environment. However, the category is loosely defined and can have many different meanings depending on who you ask.

A shift to sustainability is surely hap- Media that Meets the Mark designed to minimize environmental Sustainability has moved from a niche impact without sacrificing print perforpening. “We are absolutely seeing a continued shift toward biodegradable, interest to a clear expectation among mance,” adds Clampitt-Whaley. many customers, especially brands forecycled, and recyclable materials in Brannen feels that most of today’s dedigital print environments,” shares Mer- cused on environmental responsibility mand is centered on papers that combine and corporate transparency, according edith Clampitt-Whaley, VP marketing, recycled fiber, reliable digital print perforClampitt Paper. “The great news is that to Clampitt-Whaley. mance, durability, and compatibility with “In digital print specifically, we see paper is a natural, biodegradable, recyestablished recycling systems. “Print increased interest in papers with higher clable resource in itself.” providers and brands are looking for maJulie Brannen, director, sales and sus- recycled content, FSC-certified options, terials that support sustainability goals paper-based solutions, and substrates without introducing new production chaltainable solutions, Monadnock Paper Mills, Inc., sees momentum in relenges or workflow disruptions.” cycled and recyclable materials in At the same time, interest Brands and converters are paying closer digital print environments, particin recyclable, compostable, attention to material selection as part ularly in packaging, retail signage, and biodegradable materials is and commercial print applicaof broader sustainability, regulatory, and tions. “Brands and converters are 1., 3., & 4. Domtar’s uncoated printing and brand responsibility initiatives. office papers are manufactured with fiber paying closer attention to material from responsibly managed North American selection as part of broader sus— Julie Brannen, director, sales and sustainable forests. 2. Monadnock offers a range of tainability, regulatory, and brand solutions, Monadnock Paper Mills, Inc. paper, packaging, and labeling substrates responsibility initiatives.” engineered for digital print production.

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growing, particularly for applications where products are designed for shortterm use. “In these cases, certified compostable fiber-based materials can offer an additional pathway for responsible end-of-life recovery while still meeting the durability and print performance requirements of digital production environments,” adds Brannen.

Meredith Collins, channel marketing manager, Domtar, points out that uncoated paper is widely recognized for its strong recyclability within the digital print environment. “While some customers specifically seek paper with recycled content—often at a higher cost—many are equally focused on partnering with companies that share their sustainability values. Increasingly, customers want to source paper from organizations that demonstrate environmental leadership,

including responsible fiber sourcing and sustainable practices throughout the papermaking process.”

Clampitt-Whaley also sees growth in education around recyclability and endof-life considerations. “Customers want to understand how materials fit into broader sustainability goals, whether that’s biodegradability, recyclability, or reduced production footprint.”

Paying a Premium The caveat of purchasing eco-friendly media is often the price tag.

In many cases, Brannen finds brands are more willing to pay a premium when sustainability attributes are clear, documented, and tied to performance. “In packaging and labeling, the substrate is part of the brand experience, which makes material choice more visible.”

Brannen adds that the willingness to pay a premium is often tied to regulatory requirements or internal sustainability commitments. “When material choice supports a brand’s stated goals and delivers the expected performance in the market, the investment is easier to justify. In those cases, sustainability and results are aligned.”

Clampitt-Whaley finds that the decision to pay a premium for sustainable or eco-friendly media depends on the customer, brand, budget, and end use.

“If the end-customer requires that the material is eco-conscious, the printer is then required and held accountable to make sure they are meeting that goal.

On the flip side, if the end-customer doesn’t have a preference, it is held in the printer’s hands whether to purchase more sustainable options or not. Again,

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the great story about paper is that it is a sustainable product from start to finish."

Limitations Advances in papermaking, coatings, and digital press optimization have narrowed the performance gap between recycled or alternative fiber papers and conven­ tional substrates. "In most digital print applications, differences in print quality and runnability are largely indistinguish­ able when the material is specified for the intended press, finishing method, and end use," notes Brannen.

That said, paper-based materials will not match the extreme water- or tear­ resistance of certain non-recyclable syn­ thetic substrates. "For applications that require prolonged exposure to moisture,

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abrasion, or harsh handling, material selection should be evaluated carefully," adds Brannen.

Finishing choices such as coatings, laminations, foils, and adhesives also affect recyclability and end-of-life out­ comes. "When materials and finishes are selected with the full lifecycle in mind, recycled and alternative-fiber pa­ pers can deliver both the intended visual impact and meaningful environmental benefits," notes Brannen.

Clampitt-Whaley admits that histori­ cally, recycled paper might have looked a little grayer or dirtier than today. "Nowa­ days there are tons of recycled options

that don't look like they have any recycled content-unless you want them to, hence, fiber-added sheets."

For example, French Paper has a vari­ ety of lines with 100 percent recycled con­ tent, Neenah Paper's Environment line and Mohawk Paper's Loop line are also recycled paper lines that look and feel just as luxurious as the lines with no recycled content. Monadnock Paper offers a coated and uncoated paper that is 100 percent re­ cycled and prints well digitally.

For solutions like uncoated media, Collins shares that outside of minor file setup adjustments-such as using uncoated color values-there are gener­ ally few limitations, particularly in digital print environments.

"Alternative" Media Alternative fiber papers are becoming more common as brands look to diver­ sify responsible sourcing options. These materials may include fibers such as hemp, cotton, or other recovered fibers, often blended with recycled content.

"Recyclability and compostability de­ pend on the specific construction. Many alternative fiber papers are recyclable through mixed paper streams, but end­ of-life considerations should always be evaluated to ensure compatibility with local recycling systems," says Brannen.

Some may throw the term "tree-free" around when discussing alternative me­ dias. Clampitt-Whaley finds this to be a "touchy subject for a true paper person."

Clampitt offers a range of papers that don't rely on traditional cellulose fiber-including 100 percent cotton pa­ pers, synthetic substrates, PVC-based materials, and other innovative options.

However, Clampitt-Whaley explains "the term tree-free originally emerged from the misconception that the paper indus­ try 'kills trees' to make its products. That narrative simple isn't true."

In fact, Clampitt-Whaley believes the modern paper industry is "one of the most sustainable industrial sectors, supported

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by multi‑generational tree farms that have practiced responsible forest management for centuries. Healthy forests are essential to papermaking, which means maintaining and replanting trees is built into the very foundation of the industry. To keep producing paper, you must keep forests thriving.”

Additional Trends Trends emerging across digital print environments increasingly center on sustainability. Clampitt-Whaley explains that advancements in digital

COMPANIES MENTIONED

print technology, especially the rapid growth of high‑speed inkjet, drive demand for new types of compatible materials. “At the same time, innovations in environmentally preferable inks are gaining traction, as the industry moves away from options like traditional solvent inks that carry higher environmental impacts. Printers are also adopting more energy-efficient systems, strengthening waste-reduction and recycling practices, and prioritizing sustainable packaging—a shift that is now visible all the way to the consumer level.”

There is also heightened focus on transparency and verification. “Material choice is increasingly part of a broader conversation about responsible production and use. Brands want clear verifiable information about fiber sourcing, recycled content, energy use, and environmental management systems,” notes Brannen.

Brannen also sees growing interest in reducing waste through shorter print runs, versioning, and more targeted production, where digital print is well positioned to meet these demands.

See page 18 for more information.

“Green” Solutions

COMPANY

WEBSITE

INFO#

Clampitt Paper

clampitt.com

130

Domtar

domtar.com

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Monadnock Paper Mills, Inc.

mpm.com

134

Environmentally conscious media is of growing importance, however it is a wide and ambiguous category of substrates that is difficult to define throughout its lifespan. dps

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Cleaner Printing A Sustainable Ink Perspective

By Melissa Donovan

In the U.S., consumables like ink and media are key focuses of sustainability initiatives. From an inks perspective, reducing volatile organic compounds (VOCs) and improving recyclability and reusability of printed products are top priorities.

Addressing Demand

man-made chemicals from ink formulaR&D teams continuously evaluate raw Vendors take a distinct approach to sustions and are eliminating or minimizing materials against evolving chemical regutainability demands by working indepen- persistent organic pollutants, creating lations and global best practices to maindently and in response to global as well as safer, more environmentally responsible tain high quality and standards for prodgovernmental concerns. inks,” notes Natasha Jeremic, head of ucts,” shares Panayiotis Michaelides, For example, Domino Printing Scipiezo inks, Domino.

HSE product stewardship and sustainences’ ink development team continually Kodak made significant progress in susability specialist, Kodak. works towards sustainability priorities, tainability by developing water-based inks Ink recirculation processes also play particularly by reducing VOC emissions, free from substances of concern, includa role in sustainability. Kodak continuous as well as by investigating ink perforing PFAS, and eliminating heavy metals. inkjet technology includes the recirculamance when printing on new bio-based This results in lower material waste and tion of inks that flow from the printhead, and mono materials. improved recyclability of printed products. with some ink drops directed to the subFor corrugated printing, Domino uses “Sustainability today requires tracestrate and the rest of the ink drops capaqueous inks with very low VOC emis- ability and proactive compliance. Kodak tured and recirculated back to the ink tank sions. For continuous inkjet, it is for use. “This process enables the transitioning from harsh, convenefficient use of inks in the delivery tional to renewable, sustainable Sustainability today requires 1. Domino has taken steps to make its ink solvent. Its portfolio also includes development processes more sustainable, traceability and proactive compliance. eliminating the use of helium gas, and has food-safe, plant oil-based inks for recently been awarded My Green Lab certi— Panayiotis Michaelides, HSE product coding and marking. fication. 2. Kodak’s advanced ink formulastewardship and sustainability specialist, Kodak “We removed per- and polytions and press architectures broaden the range of compatible substrates.

fluoroalkyl substances (PFAS) or

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to the substrate, with no waste, helping the print uptime system through consistent jetting performance and print quality. By keeping ink circulating, the system helps minimize nozzle blockages, supports cleaner operation, and contributes to the overall sustainability of the printing process,” explains Michaelides.

Komori aims to achieve carbon neutrality by 2050. This goal encompasses all of its products and services. “We recognize that addressing environmental issues is a challenge common to all humankind and an essential requirement for the continued existence of a company in society. Therefore, we proactively address these issues,” notes Lance Martin, VP product marketing, Komori America.

Memjet focuses on performance as well as responsible lifecycle outcomes.

Its water-based ink portfolio supports

low-VOC operation and safer pressroom environments compared with traditional solvent or UV-curable systems.

Of course, Dr. Alison Chong, chemistry and materials department manager, Memjet, points out that emissions are only one dimension of sustainability. “We approach ink development through a lifecycle lens, with recyclability and circularity considered early in the formulation process. Memjet deliberately avoids the use of substances that may be of concern to recycling operators or state and local regulators. In our view, sustainable printing is achieved when chemistry, hardware, and workflow operate as a unified, optimized system.”

RISO Inc. originally offered a soybased ink for inkjet printing, but when soy became a high-demand crop, it started to produce an oil-based pigment ink. In the

digital duplicator space, its ink uses rice bran—which is a material that would otherwise be discarded as a byproduct. The result, RISO is able to provide an inexpensive, archival-quality ink.

“RISO’s inks are constantly improved at our facilities in Japan, and with each successive model of printer, we include those advancements. Every few years, we expand the color gamut of our inks,” states Jesse Heindl, marketing manager, RISO Inc.

More on Ink Each type of ink offers its own level of sustainability and presents benefits as well as challenges.

Aqueous-Based Ink Aqueous- or water-based inks feature a high water content, which Michaelides

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says is "inherently beneficial in helping to reduce or eliminate VOCs as well as other substances of concern in the formu­ lations compared to traditional solvent­ based inks."

Water-based inks, according to Dr. Chong, offer clear environmental and operational advantages. "Their low VOC profile supports improved indoor air qual­ ity and reduces the need for extensive solvent handling or ventilation infrastruc­ ture. Low toxicity makes them an excel­ lent choice for packaging-related applica­ tions, including food packaging."

Porous corrugated and other fiber­ based packaging, in addition to point of purchase displays, benefit from water­ based inks, as the lower VOC emissions support recyclability, points outJeremic.

Non-porous substrates present chal­ lenges when printing with aqueous-based ink. "It requires costly specialist inks us­ ing sophisticated ink technologies, which are less practical in everyday use due to the added complexity of handling the ink

in the ink system and drying it after appli­ cation," notesJeremic.

"While substrate and drying consider­ ations do need to be taken into account, when inks and printheads are engineered together, aqueous systems can deliver both sustainability benefits and excep­ tional image quality," suggests Dr. Chong.

Eco-Solvent Ink

Eco-solvent inks are considered lower impact compared to traditional solvent systems, offering reduced VOC emissions.

"They produce a significantly lower odor than hexane-, dichloromethane-, or toluene-based formulations. This makes them far more pleasant to work with and reduces the likelihood of printed products carrying residual smells. Using naturally derived, processed eco-solvents, such as limonene or ethyl lactate, eco-solvent inks offer a practical route for companies seek­ ing to reduce the environmental impact of their inks while maintaining print perfor­ mance," explainsJeremic.

Eco-solvent inks provide water fast durability for non-porous films and pack­ aging, and are often used on outdoor ban­ ners and signage.

"However, because eco-solvent inks remain solvent-based, ventilation require­ ments and certain regulatory consider­ ations may still apply. Additionally, recy­ clability outcomes may vary depending on binder chemistry and substrate pairing," notes Dr. Chong.

Oil-Based Ink

Oil-based pigment ink, according to Heindl, is very advantageous for applica­ tions in the mailing space. "Once the ink is on paper, it becomes waterproof, and will not smudge if exposed to the ele­ ments. Addresses and barcodes remain legible and scannable, no matter how bad the weather gets, which increases the de­ liverability of that mail piece."

Produced naturally, soy- and vegetable­ based inks-considered oil-based-are in­ herently sustainable. "They typically have

(i) advertiser index & companies mentioned AD INDEX

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Canon U.S.A. Domtar Eastman Kodak Comoanv Eastman Kodak Company Eastman Kodak Company Eastman Kodak Company Graphic Whizard Heidelbera

2 usa.canon.com 13 domtar.com 19 1 araohics.kodak.com 21 gra(lhics.kodak.com 23 I qraphics.kodak.com 25 gra(lhics.kodak.com 10 I araphicwhizard.com 7 heidelbera.com

Company ABG International

INFO# 202

Company Fujifilm North America

ABG International

119

Aleyant Bindwel Clampitt Paper

9

10

11 12 13 14 15

17 komori-america.us 27 mullermartini.com 11 nobelus.com 15 business.sharpusa.com 28 siqns365.com 5 standardfinishina.com 24 tecnau.com

Company Komori America

INFO# 102

Company Standard Finishing Systems

INFO#

213

HiFlow

209

Konica Minolta

205

Standard Finishing Systems

115

204

HP, Inc.

122

Memjet

104

Taktiful

203

110

HP, Inc.

111

Mondanock Paper Mills, Inc.

134

Tecnau

208

130

Hybrid Software

209

Muller Martini/Hunkeler

114

Tecnau

116

Domino Printing Sciences

100

Karlville

123

Nobelus

124

TROY

205

Domtar

131

Kodak

113

RISO Inc.

201

Ultimate Technologies

117

Felix Scholler

212

Kodak

101

RISO Inc.

103

Xerox

206

Fiery

200

Koenig & Bauer US, Inc.

112

Sharp Electronics

203

Xerox

200

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Komori America Muller Martini Nobelus Sharp Electronics Corp. siqns365.com Standard Finishina Systems Tecnau

208

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2 changeovers from minimum to maximum—and vice versa—are designed to be under a minute when switching between stored settings/workflows,” explains Sajith Pallippuram, managing director, Bindwel.

The Standard Horizon BQ-500 covers all variations of the binding market including long runs, short runs, versioned books, and book of one. “A digital thickness caliper and 21 automated sections in the binder allow for quick, repeatable, consistent, and accurate changeovers. Additionally, customized templates are created based on paper type, desired quality level, and other criteria, allowing operators to produce consistent quality with greater production 2. Output from the HP Indigo 120K Digital Press was highlighted at the recent Dscoop Rockies Edge event, held in CO this March. 3. In a variable range of +/-5 mm, the Standard Horizon BQ-500 can reach production speeds of up to 800 books per hour.

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efficiency and quality control,” notes Ed Wehbe, product specialist, Standard Finishing Systems.

For book‑of‑one production, Tecnau’s StreamFolder adjusts page length within a fixed fold pattern—e.g., two‑up 9×12 inches, 8.5×11 inches, and 8×10 inches, saving substrate otherwise lost to a single 12.5-inch cut length. For short run/many, Revolution 50 AutoSetup reconfigures between two-/three‑/four‑up impositions in under 25 seconds, “shrinking the non‑productive gap while preserving pagination integrity,” shares Dolfis.

Communication is Essential For short runs, communication between hardware and workflow tools is essential.

Stephen Sanker, national sales director, digital web, Koenig & Bauer US, Inc., points out that Koenig & Bauer directly integrates its digital printing machines

with third-party finishing and web-folding systems for delivery of complete book blocks that can be integrated into various other systems. “We support direct digital front ends for integration into all workflows.”

All Muller Martini and Hunkeler digital finishing products can be directly connected to any MIS/ MES front-end system to automate the transfer of data eliminating the need for equipment operators to read job tickets and/or rulers as data is sent directly to the machines. “This level of automation significantly reduces errors and waste, as well as minimizes set-up times and labor requirements,” says Wing.

Pallippuram explains that Bindwel has implemented a workflow interface where JDF job data can be interpreted via an executable (PC-side) component and passed to the binder over Ethernet, so the finishing step can be triggered with minimal manual entry at the machine. “If a workflow uses XJDF, the same concept applies—mapping required fields to the machine’s job template structure and pushing them over the network link.”

Most Horizon solutions, including perfect binders, are compatible with iCE LiNK, a cloud-based, postpress management system from Horizon.

This solution can provide device monitoring, KPI analysis, PM schedule/ alerts, JDF/JMF workflow support, scheduling, job creation, editing, and more. iCE LiNK also works with most MIS operating systems and interfaces with off-brand finishing systems.

Standard partners with Ultimate Technologies to offer Ultimate Bindery

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for correction or ejection. Inspection systems are integral in guaranteeing product quality without increasing labor costs,” comments Wehbe.

Muller Martini solutions incorporate the latest camera-based scanner technology in all of its digital solutions to ensure that the book blocks are complete—the front and back page are intact and match, the book blocks and covers are in the right sequence, and the content and covers match before the products even enter the binder.

Wing says this allows for automated re-sequencing or product ejection from the machine without stopping production or wasting any materials.

The failure rate of matching colors and interiors varies heavily by practice, and upstream print consistency.

“To reduce mismatch risk, 1NSTA sup-

ports quick response (QR) code/barcode-based cover recognition and a reject path if the cover doesn’t match the book block—so errors are intercepted before they become finished goods,” offers Pallippuram.

Look to Data Certain print and finishing equipment provides overall equipment effectiveness by tracking data like cost per unit.

Wehbe points out that finishing equipment integrated with Horizon’s iCE LiNK postpress management system is able to send performance and operational data such as cycles per hour, total uptime, total throughput to the cloud for analysis. “Operators and managers can see which machines are operating most efficiently while identifying where bottlenecks are occurring.”

In addition to the capability of imposing files for the digital presses or automating the set-up of finishing equipment, Wing says the Muller Martini workflow software also has a data collection suite of modules that automates the data collection process and provides meaningful real-time KPIs for performance analysis and effective business decisions.

Bindel’s 1NSTA addresses digital/ POD variability using automatic adhesive-layer control and programmable parameters such as notch interval, on approach to be tuned per job/substrate.

In addition, the gluing unit supports an interchangeable trolley-type glue tank for EVA and PUR, enabling customers to select adhesive chemistry appropriate for coated/digital surfaces and durability requirements.

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Adhesion Considerations

Battling Heat Curl

In a digital book line, binding equipment helps manage gluing adhesion challenges on digital inks and toners.

Flexibility is key to tackling this challenge. Wehbe says Horizon binders support a variety of gluing solutions for various paper stocks, offset inks, and coatings as well as digital inks and toners.

Dolfis adds that PUR remains the reference adhesive for challenging substrates, coated stocks, and long‑life books because it chemically crosslinks, maintains flexibility, and resists reactivation at elevated temperatures—where traditional EVA hot‑melt can weaken.

Due to the diversity of substrates, inks, coatings, and printing technologies; today’s perfect binding solutions need to be flexible. Wing states that Muller Martini has developed highly automated binders that incorporate integrated and exchangeable glue application systems to allow book manufacturers to effectively determine which adhesive is optimal for their process.

Tecnau’s Libra 800 perfect binder supports hot‑melt, PUR, or hybrid application—e.g., PUR on the spine with hot‑melt on courtesy scores for fast set.

PUR’s resistance to heat‑induced softening keeps bound books intact even in warm ambient conditions—think “book left in a car”—while still allowing cycle‑time agility, shares Dolfis.

Heat curl, the warping or bending of paper, is an upstream print/media issue caused by heat and pressure from the fuser.

“Curl in digital/inkjet contexts stems from moisture and solvent migration and fiber‑bond changes during wetting/ drying; research ties permanent curl to fiber–fiber bond rearrangements and solvent gradients across the sheet. Practical countermeasures include web‑tension control, decurling modules, moisture management, and alternating fold strategies to balance felt/wire side tendencies,” says Dolfis.

Tecnau’s Revolution 50’s taut‑web platform gives it precise web steering via edge sensors, ensuring perforations align squarely with minimal skew. “An operator‑adjustable decurl assembly —both directions from neutral—and buffer dancers that can release tension during idle periods help flatten the web.

StreamFolder’s plow‑folded signatures inherently alternate felt‑/wire‑side curl sheet‑to‑sheet, improving layflat at the book block. Industry guidance also supports active decurl strategies on digital presses where available.”

Technologies like Canon's ColorStream allow printers to efficiently produce, personalize, and cost-effectively print book sin small or large volumes.

The KODAK PROSPER utilizes distributed inter-station drying with

an intelligent, near-infrared (NIR) drying system to immediately dry the water-based inks between the color stations. “The combination of fast-drying inks and advanced drying technology means PROSPER Presses manage with comparatively low energy requirements for drying, which minimizes heat stress on the paper and thus moisture loss—a major cause of paper curl. The paper path and a festoon with cross-ventilation after the second printing tower also contribute to the thermal relief of the paper,” shares Howard.

The HP Indigo 120K Digital Press is designed for high-volume, automated book production, offering 6,000 sheets/hour B2 speed, non-stop printing, and 90 percent uptime, according to the company. It boosts book production productivity by 33 percent using AI-driven automation, continuous feeding/stacking, and seamless integration with finishing equipment for automated, end-to-end workflows.

Managing Labor As technology advances, the need for skilled operators is ideally reduced to help ease labor demands.

Dolfis stresses that labor remains a structural constraint and the industry response has been deeper automation from imposition to packaging, making “one operator per line” increasingly attainable

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when upstream job submission and down­ stream handling are automated. "Trends at inkjet and finishing conferences em­ phasize touchless workflows, automated splicing/roll handling, and conveyorized finishing to lower staffing ratios."

Given today's press speeds, Dolfis suggests uninterrupted material flow is the bottleneck. "A zero-speed splicing unwind-e.g., Tecnau u55-widens the time window for roll changes. When the line carries glued book blocks directly through bind/trims and into a Tecnau I Sitma packaging cell (with print-to-ship logic), one operator per line moves from 'ambitious' to 'operational."'

Pallippuram says the road to one operator is increasingly a reality-espe­ cially when setup and repeat jobs are recipe-driven. "The biggest obstacle is usually not binding complexity, but rather job variability and discipline in upstream handoff-correct barcode/QR usage, 4. The Bindwel 1 NSTA is a specialized, high-speed perfect binding machine.

consistent trimming/stacking logic, and stable print conditioning. With automat­ ed templates, scanning/verification, and ergonomic delivery, single-operator POD binding and trim-on-demand cells are practical in real production."

The biggest obstacle Wehbe sees is at the in-feed and delivery sections where it is difficult for a single operator to man­ age both ends. "However, robot-assisted solutions are entering the market that are easing the burden on operators by letting them focus on operational tasks rather than feeding and collecting."

The technologies-e.g. artificial in­ telligence, robotics, equipment, and workflow automation, etc.-exist today for a true Smart Factory. "However, the biggest obstacle that most POD custom­ ers face is the initial investment cost to develop a viable solution that is flexible enough to be operated by a single per­ son," notes Wing.

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Bindwel

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Canon

usa.canon.com

Koenig & Bauer US, Inc.

us.koenig-bauer.com

Muller Martini/Hunkeler

mullermartini.com

Tecnau

tecnau.com

HP, Inc. Kodak

Standard Finishing Systems Ultimate Technologies

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hp.com

graphics.kodak.com

standardfinishing.com ultimate-tech.com

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Howard explains that KODAK PROSPER Presses are designed for high-volume, continuous production and can be operated by a single operator per shift. "This lean operation is made pos­ sible through high levels of automation and intelligent monitoring systems. The press operator is primarily responsible for starting jobs, monitoring, and man­ aging automated print modes."

A prime example is Mercury Print Productions in Rochester, NY, a Kodak customer and educational book printer that operates several PROSPER Press­ es, including the PROSPER 7000 Tur­ bo Press. ''According to the company's CEO, John Place, all of these presses run 24/7 and are supervised by just one operator per shift," cites Howard.

Koenig & Bauer's production is en­ abled with minimal labor in comparison to other printing technologies. "We build all RotaJET systems to the specification of each customer, so we have the modu­ larity to vary the web-width for each ma­ chine. The RotaJET system is operated by one person with support for material handling at either end of the machine.

As a result of the efficiencies of the ma­ chine, our customers experience a re­ duction in overall labor, inventory, and fixed costs associated with high-volume book production at the highest levels on a wide range of paper types and ex­ tremely light paper weights for optimal performance," shares Sanker.

Book Automation The book market is shifting from scale to responsiveness with shorter average runs, volatile frontlist, resilient backlist, and tighter replenishment cycles. "Pub­ lishers raise quality expectations while leaning on digital inkjet for faster turn­ arounds and inventory risk reduction.

Industry data shows production inkjet keeps expanding its share as workflows are optimized for print on demand, with flexible finishing that varies formats at press speed;' concludes Dolfis. dps

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