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CorrExpo 2023 Preview .................................... pg. 9 Single-Pass Corrugated Printing ......................pg. 20 Water-Based Textile Inks .................................pg. 25 industrialprintmagazine.com

INFO #4

JUNE 2023

FEATURES [ 13] Digital Decoration: Direct to Object Maximize Throughput

[ 20] The Future of Corrugated Production Automation from End to End

[ 25] Water-Based Textile Inks Versatility and Environmental Sustainability Benefits

Editor's Letter [Reaching Corrugated] .......................................................... 4

Target Chart [Clean Cuts Automated Cutting Options] ...........................18

Showtime [Influential in AM RAPID+ TCT Recap] ...................................... 5

Advertiser Index .......................................................................................... 24

Showtime [Let's Rock and Roll CorrExpo 2023 Preview] ........................... 9

Companies Mentioned.............................................................................. 24

Spotlight [At the Forefront of Packaging Design].......................................11 ON THE COVER Digitally decorated drinkware produced with printers from LSINC Corporation. See page 73.

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June 2023 [ Industrial Print Magazine J 3

.RIAL 9PRINT

IN DUSTRIALPRI NTMAGAZINE.COM Volume 10, Number 3

EDrTIIR'S LETTER

REACHING CORRUGATED We are just at the beginning when it comes to the adoption of single-pass

digital printers in corrugated converting environments/print shops. Based

EDITOR IN CHIEF Thomas Tetreault 978-921-7850 EDITOR Melissa Donovan mdonovan@rockportpubs.com

on research by a combination of leading analyst firms, the team at EFI

ASSOCIATE EDITOR Cassandra Balentine cbalentine@rockportpubs.com

approximately 2,700 billion square feet printed in relation to corrugated. Ac­

ART DIRECTOR Sarah M. White swhite@rockportpubs.com

expects a global business opportunity of $176 billion in output value and

cording to the same statistics, less than one percent of this is digital today.

The opportunity is astounding in terms of what digital printing brings to

the table. Less sourcing and waste compared to conventional technolo­ gies like lithographic and flexographic printing. The ability to handle shorter

runs and versioning, which meets modern demand for quicker turnaround

times and customization/personalization.

The Future of Corrugated Production takes a look at trends in the print

space as well as addresses automation on the back end in terms of finish­ ing and material handling components. This issue also discusses corru­

gated with a preview ofTAPPl's CorrExpo event held in August in Cleveland,

OH. One of our spotlights examines an industry leader in display, print, and

packaging, Bladen Box & Display, which uses multiple ZUnd automated

cutters in its business to achieve high levels of efficiency. Read more in At

the Forefront of Packaging Design.

WEB EDITOR Melissa Mueller CONTRIBUTORS Pete Basiliere, Olivia Cahoon, Kemal Carr, Maria Conrado, Mark Hanley, Melinda Tetreault ADVERTISING SALES PUBLISHER Thomas Tetreault 100 Cummings Center, STE 321E Beverly, Massachusetts 01915 Ph 978-921-7850 x110 • Fx 978-921-7870 edit@rockportpubs.com SALES Nicole Pizzi-Cerundolo Ph 978-921-7850 x160 • Fx 978-921-7870 npcerundolo@rockportpubs.com Amanda Doyon Ph 978-921-7850 x170 • Fx 978-921-7870 adoyon@rockportpubs.com

This edition also includes information on water-based textile inks, digital decoration with direct-to-object printing, and features a textile cutting chart

listing various devices. Finally, we had a great time in Chicago in May, at­

tending for the first time RAPID + TCT. Read all about it in our recap of the event, Influential in AM.

CORPORATE & PUBLISHING OFFICE 100 Cummings Center, STE 321E Beverly, Massachusetts 01915 ROCKPORT CUSTOM PUBLISHING, LLC

Cheers,

��2� Melissa Donovan, Editor

CHAIRMAN Jeffrey Jensen PRESIDENT & CEO Thomas Tetreault CONTROLLER Missy Tyler Industrial Print magazine is published by Rockport Custom Publishing, LLC. Please send change of address forms to: 100 Cummings Center, STE 321E, Beverly, MA 01915. © Rockport Custom Publishing, LLC 2023. Reproduction by any means of the whole or part of Industrial Print magazine 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, Cana­ da 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, Industrial Print magazine 100 Cummings Center, STE. 321E Beverly, MA 01915. We cannot be responsible for unsolicited product samples.

4 [lndustfia/ Print Magazine J June 2023

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SHOWTIME

EXCITING TIMES Recap of RAPID + TCT

by Industrial Print Magazine Staff

RAPID+ TCT took place at the beginning of May in Chicago, IL at the McCormick Con­ vention Center. The event was an exciting combination of product introductions, part­ nership announcements, and a general pos­ itive atmosphere about the growing, innova­ tive additive manufacturing (AM) industry.

Wednesday's keynote, from Omar Mire­ les, research and development engineer, NASA Marshall Space Flight Center-a self­ proclaimed "lab guy"-summed it up by say­ ing "it's in exciting time to be in this field."

Notable News We asked exhibitors to share a brief recap of their time at the event.

3DCeram Sinto promoted and discussed the latest technologies and products in tech­ nical ceramics and three-dimensional (3D) printing, including the M.A:r. printer. The M.AI is a versatile machine with a robust structure able to house several shaping tech­ nologies. 3DCeram also featured the ClO00 FLEXMATIC, the newest stereolithography (SLA) 3D printer in the product line up.

Addiblast showcased its fully automated MARS 03 de-pow­ dering system for metal 3D printed parts. The event highlight­ ed the growing trend of larger and heavier build volumes in powder bed fusion. Following this trend, it plans to announce MARS 04/05 de-powdering systems to handle up to one cubic meter build volumes.

ADDiTEC unveiled its latest product, the Performance AMRC - P or Additive Manufacturing Robot Cell - Portable.

The Performance AMRC - P is a production-ready portable robot cell. Its advanced features include a potent 6kW fiber laser configured deposition head and closed loop process con­ trols, affording high deposition rates of up to 4 kg per hour for titanium. The system is capable of printing parts of up to 1.8 meters in dimension in a range of materials.

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AMFG showcased the power of its Autonomous MES solu­ tion. It presented its robust workflow software, which is a fu­ sion of seamless third-party integration and advanced automa­ tion. The company unpacked the features that make its product an end-to-end solution. From an Instant Quote functionality, to inventory and build management, and concluding with post­ processing, logistics, and shipping, it demonstrated how AMFG revolutionizes production, making it efficient and streamlined.

CNPC Powder expanded its AMP atomization technology, of­ fering higher output of PREP quality particles at costs that are inline with traditional atomization technology. Furthermore, its AM facility has been outfitted with over seven new atomiz­ ers with a combined output of ~5,000 tons of inert gas spheri­ cal atomized metal powders.

1. Picture courtesy of The Lubrizol Corporation.

June 2023 [ Industrial Print Magazine J 5

CoreTechnologie showcased its 3D printing pre-processing software-4D_ Additive, which optimizes healing, posi­ tioning, supports, texturing, automated nesting, and slicing. 4D_Additive reads CADx data from over 24 different major formats as exact boundary representa­ tion including all PMI, attributes, and his­ tory. It repairs .STL utilizing a marching cube algorithm. CAD models are saved in all common formats as well as in com­ mon slicing formats.

6 [lndustfia/ Print Magazine J June 2023

Evonik showcased one of it key 3D printing materials-INFINAM TPC co­ polyester elastomer powders-suitable for powder bed fusion technologies. It works with industrial 3D printer manu­ facturer Farsoon to bring this robust, yet flexible 3D printing powder to market. It also presented a range of new photopoly­ mers such as INFINAM RG 2000 L, an application-driven material development that meets specific requirements such as a low yellowing index or excellent

light transmission for eyewear applications.

Fabrisonic released the SonicLayer 1600, a mid-sized production machine that features a 3x2-foot build envelope.

The SonicLayer 1600 is affordable and ideal for those that are not build­ ing large parts.

Farsoon showcased the FS301M with a 305x305x400 build size, enhanced user opera­ tion, and open param­ eters and materials that allow for cost-effective production and high­ quality parts. Visitors also admired the nearly one-meter-tall rocket engine noz­ zle printed on its FS621M-4 high-perfor­ mance metal 3D printing system, ideal for aerospace, automotive, and medical industries. The company exhibited parts printed on its large-platform Flight 403 and Flight lK. Formlabs introduced three new of­ ferings-flame retardant resin, Build Platform 2L, and 3MF Support. Form­ labs' first UL 94 V-0 certified resin and first self-extinguishing material is devel­ oped to expand printing capabilities for high-temperature components. Build Platform 2L is a next-generation build platform designed with Quick Release Technology enabling users to remove large parts without tools in seconds.

3MF Support allows for smaller file sizes and the storage of multiple models in one file on existing PreForm software.

HP Inc. unveiled automation solu­ tions for the HP Jet Fusion, allowing customers to simplify workflows and re­ duce costs associated with high-volume 3D production. Additionally, HP show­ cased expanded material offerings, HP Digital Production Suite and HP Digital Production Services, allowing custom­ ers to scale 3D printed parts production.

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JEOL featured its Electron Beam Metal powder bed fusion 3D printer and parts made for the aerospace, medical, and energy sectors. Together with Cumberland Additive it announced an installation at Cumberland’s Neighborhood 91 facility in Pittsburg, PA. JEOL hosted a popular social event with a sommelier serving a selection of sake.

Lubrizol 3D Printing Solutions highlighted new ESTANE 3D TPU M88A for HP’s Jet Fusion 5200 printers; a soft, flexible and durable material suited for production parts, allowing for printing of complex geometries and challenging lattice structures.

Impossible Objects launched the CBAM 25 3D printer and the SME AM Industry Achievement award was presented to Jeffrey DeGrange, CCO, Impossible Objects.

Mantle received the SME AM startup technology award. Mantle is revolutionizing precision tooling with its metal 3D printer designed specifically for toolmaking. The company’s 3D printers are an efficient way to produce mold and die inserts with the accuracy, surface finish, and tool steel properties demanded by toolmakers.

Markforged unveiled for the first time in North America its new binder jet workhorse the PX100. From its acquisition of Digital Metal, Markforged has doubled the print speed and throughput of the Digital Metal DMP Pro. The PX100 enables manufacturers to become industry leaders by designing and fabricating previously un-makeable parts and unlocking customization at scale. It is capable of print speeds of up to 1,000 cm3 per hour and has a range of available materials.

Meltio showcased its unique wirelaser metal 3D printing technology.

2. Xact Metal attended RAPID + TCT with multiple software-centric announcements. 3. Nexa3D launched its XiP Pro industrial 3D printer. 4. Fabrison-

ic released the SonicLayer 1600, a mid-sized production machine that features a 3x2-foot build envelope.

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4 Meltio’s solutions, the M450 metal 3D printer and wire-laser head that integrates with a CNC machine and robotic arm, help automotive, aerospace, marine, military, engineering, and oil and gas manufacture and repair metal parts made of stainless steel, titanium, nickel, and invar. Thanks to this technology, industries reduce costs and gain efficiency and productivity.

Meteor Inkjet showcased a range of printhead drive electronics and software, as well as demonstrated powerful drop visualization tools and unveiled ShellPro, patented technology offering step-function savings in the energy and materials required to create complex 3D structures by binder jetting. nTop announced the next major update of its flagship product—nTop 4. nTop 4 introduces Field Optimization, a new generative design technology to help engineers navigate the number of design parameters introduced by these complex engineering problems, accelerating decision making and improving part performance.

Nexa3D launched its XiP Pro ultrafast industrial 3D printer, providing the highest daily production throughput and lowest total cost of ownership in its class. Featuring print speeds exponentially faster than the traditional SLA and digital light processing-based technologies, more powerful print engine, and a 19.5-liter build volume, the XiP Pro delivers previously unattainable production capabilities for industrial users, according to the company.

Prima Additive enjoyed its first participation at RAPID + TCT. After several years of activity in Europe, today it offers its solutions for metal AM with laser powder bed fusion and directed energy deposition technology, as well as a full suite of services in North America.

Quantica showcased its NovoJet C-7 open system. Beyond its sleek design, what captivated attendees was the capability of the NovaJet C-7 to combine diverse materials. The heart of Quantica’s technology lies in its NovoJet printheads, which enable the printing of

June 2023 [ Industrial Print Magazine ] 7

5 higher viscosity materials, resulting in higher performance end-use parts and products. Complementing the display was the presence of its JetPack material 5. Xometry presented its Xometry Instant Quoting

Engine, which offers instant pricing and lead time estimates for more than a dozen manufacturing processes. 6. 3DCeram Sinto, a turnkey provider for additive manufacturing ceramics, had a successful show at RAPID + TCT.

jetting kit, along with an array of multimaterial print samples.

Roboze presented case studies demonstrating how it is transforming the industry paradigm with super polymers.

The event also highlighted ADDMAN’s entry into the Roboze 3D Parts Network, a U.S.-based provider of a range of manufacturing solutions. The objective of this collaboration is to enhance

its industrial manufacturing capabilities using AM systems.

Roboze 3D Parts, an expanding network, intends to hasten the world’s transition towards sustainable production by eliminating physical warehouses, enabling on demand and just-intime production of parts, and delivering them where necessary.

UltiMaker unveiled a new brand identity, with a spotlight on its solutions for manufacturing and product development— Method X and the flagship S7, the newest and most versatile 3D printer on the market. From polymers to metal, UltiMaker also highlighted its extensive 3D printing materials portfolio, showcasing what its printers can do for any application.

Xact Metal attended the event with multiple software-centric announcements. Pursuing its mission to make metal 3D printing more affordable and accessible, Xact Metal announced a new partnership with Oqton to offer 3DXpert and MOS software packages while also extend its current software partnership, Materialise Magics. Additionally, Xact Metal rolled out an AIpowered layer-wise monitoring add-on called Smart Layer. This product can automatically identify print anomalies in real-time, preventing build failures before they occur.

Xometry presented its Xometry Instant Quoting Engine, which offers instant pricing and lead time estimates for more than a dozen manufacturing processes. The platform comes with built-in tools and customization options. Xometry showcased several manufacturing projects made from different materials, including polymer and metal 3D printing.

2024

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8 [ Industrial Print Magazine ] June 2023

RAPID + TCT is on the move. Next year’s event takes places in Anaheim, CA. IPM

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SHOWTIME

GET YOUR ROCK & ROLL ON CorrExpo 2023 in OH

by Industrial Print Magazine Staff

CorrExpo 2023 is planned for August 28 to 30, 2023 at the Huntington Convention Cen­ ter in Cleveland, OH. Cleveland is home to the Rock & Roll Hall of Fame, which attendees are invited to visit during the evening of Tues­ day, August 29. Entry to the Rock & Roll Hall of Fame is included with full 2023 CorrExpo conference registration.

Organized by TAPPI-an association for the worldwide pulp, paper, packaging, tissue, and converting industries-CorrExpo 2023 is part seminars, part exposition. The event welcomes Bob Chapman, chairman/CEO, Barry Wehm­ iller for the kick-off keynote address on Tuesday, August 29. Chapman's remarks will focus on leadership, with the keynote titled Truly Human Leadership: The Skills and Courage to Care.

Also of note is the What's New?/Tech Talks sessions, which return based on popular de­ mand. These are held on the main stage of the exhibit floor to increase visibility. Look for Cor­ rExpo 2023 exhibitors to share information on new technologies, products, or services in seven minute presentations.

Worthwhile Exhibitors Speaking of exhibitors, the show floor includes an array of ven­ dors specializing in the corrugated space, from digital print­ ers to finishing components, and the software that drives the entire process.

A.G., booth 307, reimagines what speed, productivity, and profitability could look like in your facility. To take advantage of full-line productivity-both now and in the future-you must reimagine your floor with machine assets that are fast, fully integrated, digitally enabled, and eco-conscious. At CorrExpo 2023, A.G. showcases its innovative pre- and post-converting equipment and digital technologies engineered for the fastest production lines of today and tomorrow. Attendees can inter­ act with A.G.'s eBreak bundle breaker and eXT stacker front

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end system through DUO digital twin technology, its GO AG digital productivity software, and custom factory planning sim­ ulations through SIMCORRA technology. With a full suite of solutions including bundle conveying systems, load formers, and bundle breakers A.G. is more than stackers. Reimagine A.G. as your full line solutions partner for ultimate productivity and innovation. INFO# 160 Baumer hhs, booth 407, features its CorrBox solution. Make a stronger, lighter, and more sustainable corrugated blank us­ ing less glue by implementing a brick-style pattern developed

by Baumer hhs that creates a stronger bond. The new all­ electric PX 1000 applicators with over a billion in cycle life 1. Baumer hhs features its CorrBox solution in booth 407 at CorrExpo 2023.

June 2023 [ Industrial Print Magazine J 9

can easily apply the pattern with clean cutoff and accurate placement. The GDX 1000 sensor shows your customer that every box was properly glued, and it is not affected by any color or printing background and does not require UV tracers to operate. Come and learn how to significantly reduce adhesive usage and still make a stronger bonded box by innovating to the Baumer hhs CorrBox solution. INFO# 161 Durst, booth 822, consults corruga­ tors and converters about moving to digital inkjet with UV and Durst Water Technology multi-pass printers, as well as increasing print capacity and func­ tionality with single-pass digital print­ ing. The PS 350 is the hybrid solution for roll and board printing up to 11.5 feet and reaches in the high-speed ver­ sion a productivity of up to 7,000 square feet per hour. The PS 250 WT repre­ sents the new generation of printers incorporating Durst Water Technology.

The system prints from flexographic 2. Kento Digital Printing, booth 622, shares more about its Kento Hybrid system. 3. With the Delta SPC 130, Durst adapts its single-pass technology for the corrugated industry. Learn more in booth 822.

1 O [lndustfia/ Print Magazine J June 2023

quality up to superb lithographic quality with odorless ink. Durst Water Technol­ ogy is highly suited for a range of cor­ rugated packaging and display applica­ tions. With the Delta SPC 130, Durst is now adapting its single-pass technology for the corrugated industry. The system combines a well-engineered mechani­ cal design with easily accessible sub­ assemblies and selected components to guarantee durable quality, high perfor­ mance, and reliability. INFO# 162 HP PageWide Corrugated, booth 607, delivers field-proven digital printing solutions that enable faster time-to­ market, consistent offset print quality, easy customization with variable data, and runs of any length using both web­ fed and sheetfed technology. HP solu­ tions also support worry-free production with water-based inks and contribute to converter and brand circular economy goals. INFO# 163 Kento Digital Printing, booth 622, promotes the Kento Hybrid system, which is especially for corrugated and saves up to 80 percent in ink costs. Ken­ to Hybrid uses flexographic for print­ ing large areas of solid backgrounds,

white, or metallic colors that would be expensive or impossible with cur­ rent digital printers; and minimizes setup times and saves cost by digi­ tally printing high-resolution images without expensive four-color plates.

Kento Hybrid combines one or more flexographic printing units with a sin­ gle-pass inkjet printer, and an option­ al rotary die cutting module, the first of its kind to be installed in any digi­ tal printing machine. The first Kento Hybrid is in a state-of-the-art cor­ rugated plant near Valencia, Spain, and the second one is up and running in Bettendorf, IA. Both Kento Hybrid print­ ers are available for on-site or remote demonstrations. INFO# 164 Oxytech, booth 123, showcases its Corrset-100 infrared (IR) drying system, which aids in the goal of increasing cor­ rugator speed by improving the drying process of starch during corrugating.

With the IR system in place, starch dries faster and more consistently. Because IR energy evaporates water from the starch faster and more consistently less is needed. The result is that the speed of the corrugating process may be in­ creased by up to 30 percent. Oxytech's Lamset-65 drying system aids in the goal of increasing lithographic lamina­ tor speeds and a faster/better bond. The result is that the speed of the laminating process increases and achieves a posi­ tive bond without having to wait for the PVA to eventually dry. INFO# 165

Ready to Rock Planning to head out to OH? Get ready to rock at CorrExpo 2023. As a media spon­ sor of the event Industrial Print magazine looks forward to covering it! /PM

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PROTOTYPING TO PRODUCTION Digital Cutting from End to End

by Melissa Donovan

Packaging production companies of all shapes and sizes benefit from digital cutting solutions. Businesses often start small, adding digital to their prototyping and sample making departments. While others begin at the other end of spectrum, directly tackling production processes by implementing efficient, reliable digital cutting systems.

Keep it Consistent In business since 2004, Bladen Box & Display of Mansfield, Nottinghamshire, U.K is known for its innovation in display, print, and packaging.

1 James Bladen, managing director, Bladen Box, has over 30 years of experience in the package design space.

The first digital press was installed in 2010, prior to that the When the company began, it employeed one and today company outsourced its digital printing work. “I have always boasts a staff of ten working out of a 17,000 square foot lobeen interested in digital as a cleaner technology with an undercation. Geographically serving mainland U.K., Bladen Box is standing that it will replace screenprint, flexography, and lithoself defined as a supplier and manufacturer of point of sale graphic printing. I could see the potential for digital and viewed solutions, digitally printed displays, exhibition kits, and ban- some early attempts at it for prototyping in the mid 1990s in an ners and signage. old life within the packaging industry,” explains Bladen.

“We are known for our attention to detail, excellent customDespite not integrating digital print until the 2000s, Bladen er care, industry knowledge, and quick turnaround service for started utilizing digital cutting systems in 1994. Prior to that, bespoke, low- to medium-volume requirements with the highgraph paper, pencil, and scalpel were tools of choice to finish est level of consistency,” says Bladen. a project. Automated, digital cutting systems were a big allure To meet the needs of its customers, the company utilizes a and the company turned to Zünd to meet its need for an effleet of digital printing devices including Canon Arizona 360 ficient, consistent finishing process. Zünd G3 L-3200 and G3 GT and Arizona 440 GT flatbed printers, an InkTec JETRIX M-2500 cutters are used for production.

LXi8, and an Epson In 2022, Bladen SureColor S80600L. Box added a Zünd S3 The first three printers L-1200 to replace its are ideal for Bladen sample maker. “HavBox’s corrugated flat ing the same cutting sheet work. The Epson technology for sample is used when corrugat1. U.K.-based Bladen Box is a ed work requires comsupplier and manufacturer of point of sale solutions, digitally plementary display printed displays, exhibition products like posters, kits, and banners and signage.

— James Bladen, managing director, Bladen Box shelf strips, and popIt works with multiple cutters from Zünd. up banners.

Digital technology enabled us to go into manufacturing and create a niche between the old worlds of screenprint and a packaging sheet plant.

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June 2023 [ Industrial Print Magazine ] 11

making allows us to be consistent in quality from prototype to production. I also like the tool compatibility Zünd offers from one cutter to another,” shares Bladen.

The Zünd S3 L-1200 meets all of Bladen Box’s goals thanks to its roll feeding capability. “We initially looked at adding another G3 but having seen the Zünd S3 range, it ticked all the boxes as the perfect cutter for sample making. The S3 also gives us the capacity for small format lowvolume production while maintaining a small footprint in the factory,” says Bladen.

C O M PA N I E S M E N T I O N E D

With the three Zünd devices on site, Bladen Box cuts 90 percent of its work digitally and die cuts ten percent.

Bladen Box also implemented Zünd Connect software when it purchased the Zünd S3 L-1200. The tool allows the company to monitor all of the Zünd devices at once and provides an overview on all of its usage. “Having a real-time dashboard with cutter productivity and downtime is a game changer for us. We can now create job lists more efficiently and increase our productivity,” admits Bladen.

See page 24 for more information.

INFO# Company

Website

145

Canon Solutions America

csa.canon.com

146

Epson

epson.com

147

InkTec

jetrix.co.kr

148

Zund America, Inc.

zund.com

Future in Mind Looking toward the future, Bladen Box is well positioned to benefit from its current Zünd cutters. “Digital technology enabled us to go into manufacturing and create a niche between the old worlds of screenprint and a packaging sheet plant,” says Bladen.

But that isn’t to say he isn’t keeping up-to-date on the newest technologies. With Zünd recently announcing the Q-Line with board handling system – BHS180 and UNDERCAM at press time, we asked him what he thought of the disruptive technology.

“It looks awesome. I can see down the line this as the next leap frog in what we will do. I think this is something we will look into as we become more automated,” notes Bladen. IPM

#2 12 [ Industrial Print Magazine ] June 2023

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D . irec t. t □.. . . □. .bj.e.c.t

by Melissa Donovan

E

fficient production is good for a company's bottom line, aids in sustainability, and places less burden on press operators and the rest of a business' staff. In manufacturing, a number of notable trends like shorter runs and customization benefit from the effectiveness of digital print. Specifically; in terms of product decoration, printing directly to an object has never been more cost effective for on demand requests.

Direct-to-object (DTO) digi­ tal printers on their own are productive, but adding inline pretreatment boosts throughput even further. Pretreatment in general is necessary to enhance

ink adhesion to a surface with a low dyne level. It also aids in preventing chipping, peeling, or fading of a graphic. Placing the process-whether corona, plas­ ma, flame, pyrosil, or jettable primer-directly inline with the printer provides an even greater level of efficiency.

Instrumental Indeed DTO printers are instrumental in manufacturing, especially for any vertical looking to decorate their pre-manufactured prod­ ucts to capitalize on shorter runs and customization.

"Consumers demand more personalization and higher qual­ ity on all prints. This includes

Left: Koenig & Bauer Kammann's pretreatment system using flame and Pyrosil is the K31 A-FS, combined with its OTO printers, the process is ideal for decorating glass.

June 2023 [ Industrial Print Magazine J 13

setup costs, and increasing production efficiency. Additionally, these printers require less ink and consumables, further reducing overall costs,” says Makrinos.

DTO digital printing presents a new level of flexibility as well. “It enables quicker changeovers from one SKU to another, increasing machine uptime. This flexibility also permits products to quickly respond to seasonal or regional variations,” shares Peter Baldwin, marketing manager, Engineered Printing Solutions (EPS).

1 items traditionally imprinted with a one- or two-color logos. Consumers want full-color images printed to the same substrate,” shares Sydney Willis, director, sales and marketing, LSINC Corporation.

Paul Bolduc, president, Koenig & Bauer Kammann (US) says the main drivers for DTO digital printing include customization, creating new markets, and the opportunity to provide photorealistic images.

Digital print offers fast production times. “Digital DTO printers allow manufacturers to print directly onto products, eliminating the need for timeconsuming and costly manual decorating methods. These printers print highquality images, text, and graphics onto a range of substrates, including plastic, glass, metal, and ceramics, in a matter

of seconds,” explains Jessica Makrinos, marketing manager, Inkcups.

“Many manufacturers are switching from labeling to direct print. Instead of investing in millions of labels, you can almost instantly change what you are printing on the bottle without worrying about old inventory. This gives manufacturers more freedom with their products,” add L. Wilson Lee, director of business development and Mark Plantier, VP marketing, Enercon Industries Corporation.

Another advantage to using digital print—reduced costs. “Traditional decorating methods, such as screen or pad printing, can be costly and require significant setup times, especially for smaller production runs. DTO digital printing eliminates the need for expensive tooling, reducing

Adopting Digital DTO digital printers in manufacturing environments is on an upward trajectory.

Makrinos cites a report by MarketsandMarkets stating that the global digital printing market is expected to grow from USD $24.8 billion in 2018 to USD $35.1 billion by 2023, with a compound annual growth rate of 7.1 percent. The report also states that packaging and label printing sectors are the largest contributors to the digital printing market, with the highest growth rate.

Part of the reason for this growth, according to MarketsandMarkets, is because digital printing technologies, including DTO printers, are well suited to the packaging industry’s requirements, such as short-run printing, customization, and fast turnaround times.

“It’s difficult to give an exact percentage of the adoption of DTO digital printers in manufacturing, as it varies across different industries and regions. However, it’s safe to say that the adoption of these printers is steadily increasing as manufacturers recognize the benefits they offer in terms of customization, speed, quality, and cost effectiveness,” shares Makrinos.

Lee and Plantier’s best guess at growth numbers, “ten to 20 percent adoption at 1. Enercon’s Blown-ion plasma is used for either conductive or non-conductive surfaces. 2. The EPS

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14 [ Industrial Print Magazine ] June 2023

BottleJet Cylindrical Inkjet Printer is a multi-color, UV LED, high-resolution industrial inkjet printer designed for decorating cylindrical bottles.

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this point but that number will continue to grow. Along with the flexibility of changing print, the overall cost will be less in the long run.”

“In the market of decorating glass and plastic articles, I would say the adoption is in the 15 to 20 percent area.

As the technology develops, I believe the percentages will continue to increase,” agrees Bolduc.

Growth areas differ by market. “In the promotional market, almost everyone we speak with has some type of DTO digital printer. In the wine and spirits market, which is more traditional, digital is in its infancy. I suspect that just as every commercial printer eventually adopted some type of digital device, the DTO space will follow,” forecasts Willis.

Despite growth, there are barriers to entry. “The initial investment cost for these printers can be high, and the technology is still relatively new, which may make manufacturers hesitant to switch from traditional printing methods,” admits Makrinos.

Accelerating the Move to Digital With manufacturers not yet fully embracing DTO digital printing, it’s imperative that players in this space headline education about the technology’s advantages.

At Enercon, there is a movement to educate customers on the benefits of surface treatment plus printing. It works with printing companies to make sense for both sets of customers.

Inkcups plays an important role in accelerating the evolution of digital print. It is committed to educating the market about the benefits of DTO printing and how it can improve product branding, reduce waste, and improve sustainability. This includes participating in industry events, offering training and support, and sharing thought leadership content on its website and social media channels.

Koenig & Bauer Kammann takes what Bolduc refers to as the “long approach,” spending time developing solutions for

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customers. “These solutions include designing better inline pretreatment solutions, testing products in our lab, and working with multiple ink suppliers to continue to develop and use the best consumables for the application.”

LSINC printers produce high-speed, high-resolution images in full color. The look and feel of samples gets even the most traditional printer interested in exploring digital technologies. The company carries multiple patents and continues to breakdown the barriers to adoption in the market.

Manufacturers looking to complement or replace traditional decorating practices have a few set standards, according to Makrinos, when it comes to implementing digital devices. These include quality, compatibility, and scalability. If these are met, the path to digital is clearer.

“The quality of DTO digital needs to be as good as or better than traditional printing methods to ensure that products look their best.

DTO digital printing should be compatible with a range of materials and products to be useful for any manufacturer. It must be scalable to accommodate large production runs and meet the demands of high-volume manufacturing,” explains Makrinos.

Ac c o r d i ng to Willis, “current manufacturers need assurances that customers will

accept the final product. They want to know if the ink holds up as well as their current technology. The early adopters are in a position to take market share from those that are lagging. The demand for high personalization and a ‘greener’ approach to printing are already moving manufacturers in this direction.”

Baldwin notes that DTO digital printing requires a very different skillset than older analog methods of product decoration. The prepress workflow requires graphics skills that most pad print machine operators don’t have to worry about.

Bolduc points out that while many manufacturers have dipped their toe in DTO digital printing, some have also experienced disappointments in the technology. “Many equipment manufacturers claim specifications under perfect conditions, which in manufacturing conditions cannot be met.”

“Change is always difficult to embrace but as more manufacturers become

#1 June 2023 [ Industrial Print Magazine ] 15

*

James Bullington, CTO, LSINC, says

better color vibrancy, sharper details, and

pretreatment is also used for its "ability to

improved durability of the printed image:'

withstand ink fastness tests that simulate

Not all printers include inline pretreat­

what the media needs to go through after

ment and not all applications benefit from

initial manufacturing, during final finish­

pretreatment applied inline. "Many manu­

ing processes, shipping, or dishwashing."

facturers print to multiple media types

There are many variations of how

that require different types of pretreat­

the pretreatment process works. It can

ment, which is why inline isn't necessarily

occur near line, offline, or inline to the

useful;' notes Bullington.

digital printer.

is necessary or preferred depends on the

mary driver of inline solutions rather than

specific printer and the type of material

part topography. The type of substrate is

being printed on. Some materials may re­

the other factor-even seemingly-specific

quire more extensive pretreatment than

formulations such as HDPE can have dif­

others, and some printers may be able to

ferent ingredients that affect ink adhesion."

achieve high-quality results without inline

Most of EPS' single-pass inkjet printers

pretreatment," notes Makrinos.

have some form of inline pretreatment in

3

order to maximize throughput.

aware of the potential savings and ease

"Whether or not inline pretreatment

Baldwin says "throughput is the pri­

"Inline pretreatment is preferred be­

Convenience and Efficiency There is a trend toward newer DTO digital

of the change, more will make the invest­

cause it is the best guarantee to ensure a

printers running pretreatment functions

ment," admit Lee and Plantier.

printable surface is presented to the print­

inline. Having this as part of the overall

er. Automation eliminates human error,

process is beneficial and cost effective.

Stepping lnline

improves process consistency, and boosts

"With the issues of finding people,

Pretreatment is an important part of

quality while increasing throughput;' share

inline pretreatment eliminates extra han­

DTO digital printing. Many times a pre­

Lee and Plantier.

dling. In a production situation I would

manufactured object relies on a pretreat­

Koenig & Bauer Kammann provides

ment to enhance adhesion of the ink to

inline solutions for all of its customer ap­

In a labor market where good help is

plications, and for most if not all applica­

difficult to secure, Lee and Plantier also

the surface of the item in question.

consider this a must;' admits Bolduc.

"Pretreatment is generally used in

tions inline is preferred. "The reason most

see inline pretreatment as a huge advan­

digital printing to improve adhesion be­

customers or applications consider inline

tage. "Inline surface treating can eliminate

tween the ink and the substrate. This is

is that it reduces the number of times

primers and other manual surface prepa­

particularly important for substrates with

customers must touch the article, thereby

ration processes. Automation reduces

non-porous or low-energy surfaces, such

increasing manufacturing efficiencies," ex­

labor cost and allows manufacturers to

as glass or plastic, which can be difficult

plains Bolduc.

reallocate employees to higher value pro­

for ink to adhere to without proper prepa­ ration;' explains Makrinos.

3. LSINC printers can produce high-speed, high-res­ olution images in full color. 4. lnkcups' Helix printer is available with inline pretreatment options. Custom­ ers are able to choose between corona, plasma, or jettable primer.

COM PAN IES MENTION ED INFO# Company

According to Makrinos, inline pretreat­ ment is generally preferred because it is

customer satisfaction and means less

more streamlined. "By applying the pre­

quality issues and rework:'

treatment solution directly before printing,

"lnline pretreatment is a crucial step

the printer ensures the substrate is prop­

that improves print quality, reduces costs,

erly prepared and optimized for the ink to

increases productivity, and expands print­

adhere to the surface. This can result in

ing capabilities;' explains Makrinos. ment is not only beneficial or cost effec­ applications where throughput speeds

Website

Enercon Industries Corporation

enerconind.com

152

lnkcups

inkcups.com

153

154

Engineered Printing Solutions

Koenig & Bauer Kammann (US) LSINC Corporation

16 [lndustfia/ Print Magazine J June 2023

Baldwin argues that "inline pretreat­

·p�seepage24for moreinformation.

150 151

cesses. Improved quality also increases

tive but rather essential for single-pass

epsvt.com

are high. Inline solutions also eliminate

kammann.de/en

ment such as labor and inventorying half­

lsinc.com

the costs associated with offline pretreat­ finished goods;'

industrialprintmagazine.com

"Inline pretreatment ensures a level of consistency through better process con­ trol, which is not possible in manual appli­ cation," adds Bullington.

Pretreatment Processes Pretreatments are adhered using corona, plasma, and flame or Pyrosil processes, as well as jettable-from the printheads­ primer. The method used depends on the substrate or material being printed to, for example glass or metal makes a difference.

"Pretreatments such as flame and flame with Pyrosil are more often used on glass where cold end coatings and con­ taminants need to be removed so they do not negatively effect the digitally applied ink. Corona and plasma are more often applicable to plastics where a flaming process negatively effects the structure of the media. Spray and jettable primers are used on a wider cross section of me­ dia since they do not affect the structure of the media," shares Bullington. A majority of LSINC clients have chosen to utilize an inline flame with a jettable primer.

Lee and Plantier explain that plasma and flame pretreatment prepare a surface by cleaning, etching, and functionalizing the surface to increase surface energy and improve wettability. These surface treating technologies are preferred over manual and chemical processes because they do not expose workers to hazardous chemi­ cal primers, and the treating process can be automated.

Enercon's Blown-arc and Blown-ion atmospheric plasma is often utilized in these situations. Blown-arc is used for lower speed lines printing on non-metallic surfaces. Blown-ion plasma is for either conductive or non-conductive surfaces.

Newer Blown-ion technologies treat wider areas in a singular pass with more consis­ tency than technologies that rely on a ro­ tating motion.

"Both plasma and corona change the surface tension of the substrate, but in different ways. Corona uses an electri­ cal charge to alter the surface tension,

industrialprtntmagazine.com

whereas plasma uses the plasma of a flame.

Due to the nature of the two, plasma is the more powerful. Jetta­ ble primers are avail­ able to promote adhe­ sion to a number of different substrates," notes Makrinos.

Inkcups' Helix and Double Helix DTO printers are available with inline pretreat­ ment options. Cus­ tomers are able to choose between corona, plasma, or jet­ table primer.

Koenig & Bauer Kammann designs systems with all of the above-the ba­ sic consideration is the adhesion of the ink. "One other option is flame or Pyrosil, which is primarily used on glass and ce­ ramics. Our pretreatment system using flame and Pyrosil is the K31 A-FS or K31 A-XS," says Bolduc.

Depending on the system, the user may be able to switch between corona, plasma, flame, or jettable printer on the fly. This is advantageous for manufacturers looking to DTO digital print for decorating mul­ tiple surfaces like plastic, metal, and glass using the same device.

"Generally speaking, most printing lines rely on one specific technology for their pretreatment needs. It is possible to have multiple technologies on a single line if needed. In most cases, these changes can be made in the field. If you can print on an item based on various geometries, the surface treating portion will also work," ex­ plain Lee and Plantier.

EPS' field service technicians are able to retrofit different pretreatment methods to machines in field as end user needs change. However, "since the pre­ treatment method is selected during the design process, having previously tested and found the ideal pretreatment method as part of the proof-of-concept sampling

process, these modules are not typically designed to be user-swappable in the field," explains Baldwin. '½!though switching between pretreat­ ment systems is possible, we typically equip a machine with the most robust pretreatment system for the application and allow the customer to tum off the items that are not needed," adds Bolduc.

Pretreatments like corona, plasma, and flame are specialized stations that exist in the production line feeding the printer, according to Bullington. This means they can be turned on or off based on the substrate. However, "more often than not as production speeds increase one sees that the printers are mated to production lines that feed similar me­ dia to the printer to reduce changeover times. So one is less likely to see a line that needs all types of pretreatments, and instead a line is configured around one specific type."

Maximum Efficiency DTO digital printers and the process of running pretreatment inline maximizes throughput in a production facility. With more brands looking to offer customized options of their products, it makes sense to adopt this technology to meet the growth in on demand personalization.

Visit industrialprintmagazine.com to view a webinar on this topic. 1PM

June 2023 [Industrial Print Magazine J 17

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135 Matic S.A maticmachines.com

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141 Trotec Laser troteclaser.com

142 Yin USA Inc. yinusainc.com 143 Zünd zund.com

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#5 industrialprintmagazine.com

June 2023 [ Industrial Print Magazine ] 19

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times are becoming short­ er-all impacting produc­ tion. Planning complexity, the circular economy, and food safety requirements for packaging are other factors," explains Chuck Slingerland, corrugated sales manager, Durst US. Many substrates/ma­ terials are used in pack­ aging. Corrugated in par­ ticular is still primarily printed using convention­ al technologies, but uses single-pass digital print­ ers. Complemented by automated handling sys­ tems to maneuver heavy stacks of corrugated materials, convert­ ers and printers adopt these processes as they are both cost-effective and ac­ cessible methods of production.

Instrumental for Corrugated Single-pass digital printers are instru­ mental for today's converters and print­ ers involved in corrugated.

There is increased demand for vivid designs on packaging, something single­ pass digital printers can deliver.

According to Adi Shorer, product and marketing manager, HP PageWide Industrial, Post-Print, "digital print enables converters to provide high­ quality packaging that excites consum­ ers. Whether it's detailed and person­ alized designs on shoe boxes or food and beverage packaging that excites on storytelling, the agility and flexibility of digital print enables innovative brand campaigns that excite consumers and ultimately, boost engagement."

"Single-pass digital printing increases a converter's output of high graphic cor­ rugated packaging without the sourcing and waste associated with lithographic laminated labeling or the high cost of flexographic printing plates. The ability to go from file to print enables just-in-time

industrialprtntmagazine.com

shipping. With digital printing, job set up and changeovers are executed in min­ utes, and the first sheet is sellable with minimal waste compared to traditional analog printing," explains Slingerland.

Sometimes these implementations are a collaborative effort, combining digi­ tal with analog technologies like flexog­ raphy, which makes for a hybrid method.

"Incorporating hybrid, single-pass technology offers cost savings and increased margins, higher quality of print, especial­ ly solid colors, and the ability to offer cus­ tomers high graphic printing without the high investment and operator skill level needed for most analog machines offered today," explains Lloyd Kent, VP sales and operations, KentoNorth America.

Digital is advantageous for sustain­ ability reasons. According to the Markets and Markets report, "unlike conventional printing, digital printing does not use film plates or photo chemicals, which eliminates the prepress stages between the digital document file and the final print. Furthermore, digital presses do not emit harmful emissions. This eases their overall energy consumption."

In regards to the EFI Nozomi digital single-pass printer for example, "this tech­ nology passed a variety of certifications

including but not limited to the Fogra certificate on energy consumption, which states that this machine uses up to 30 per­ cent less energy than other equipment, and the OCC certificate of repulpability and recyclability by Michigan University;' adds Jose Miguel Serrano, global busi­ ness development director packaging, EFINozomi.

Making Progress We are at the tip of iceberg when it comes to the adoption of single-pass digital printers in corrugated converting environments/print shops.

"The first digital single-pass post­ print presses for corrugated were intro­ duced to the market in 2016, generating interest but a lot of suspicion from the traditional industry," notes Shorer.

Based on research by EFI as well as by analyst firms such as LT. Strategies, InfoTrends, IDC, ICCI, and FEFCO, Serrano expects a global business op­ portunity of $176B in output value, and approximately 2,700 billion square feet printed. Less than one percent of this is digital today.

1. ZUnd raises the bar for industrial, pallet-to-pallet production with the new Q-Line with BHS180 Board Handling System and UNDERCAM.

June 2023 [ Industrial Print Magazine J 21

"We have seen our customers' busi­ nesses grow by more than 80 percent year over year. This shows us that digital adoption is significantly increasing as more converters discover and embrace opportunities that come with single-pass digital print," he continues.

Slingerland notes that over the last six years, single-pass printing has tran­ sitioned from early adoption to a fully ac­ cepted print production method because of evolved ink jetting technologies, in­ creased resolutions, as well as increased printer reliability and technical uptime.

"In order to be competitive and offer similar print solutions, more converters 2. The Elitron Kombo TAV-R is a fully automatic cut­ ting plotter with integrated loading, cutting, and unloading system for packaging and display. 3. The Durst Delta SPC 130 can be configured with up to six colors, printing any length of corrugated cardboard or paper media of up to 12 millimeters in thickness.

4. The Nozomi 14000 LED printer is EFl's second generation of digital corrugated printers and fifth generation of high productivity single-pass industrial printers. 5. Bland Farms was the first company in the industry to market sweet onions year round. It relies on its corrugated display printing partner, Complete Design and Packaging, to print quality graphics on corrugated using an EFI Nozomi single-pass press.

22 [ lndustfiaf Print Magazine J June 2023

will add single-pass printers to their portfolio of solutions. The cost per click and consumer packaged goods brands continue to embrace single­ pass printing as it adapts to smaller minimum order quantities, regionaliza­ tion of packaging and campaigns, and increased package graphic changes," continues Slingerland.

Despite growth, Kent says that under 0.5 percent of worldwide corrugated production is handled via digital print.

The reason-the cost of digital ink.

"Hybrid technology allows for huge ink savings, up to 80 percent, which means more business can move to single pass, adding to the bottom line and enhancing a machine's return on investment (ROI)," continues Kent.

What Will it Take?

Accelerating the evolution of single-pass digital corrugated printing takes educa­ tion in many forms. It is through instruc­ tion and real world success stories that corrugated converters and printers learn to embrace single-pass digital printing.

Each vendor offering solutions in this space is playing a part in the growth.

Durst provides print­ ers with a detailed total cost of ownership calcu­ lation to help embrace the change of single­ pass printing as part of their processes. It offers transparent production data driven by Durst Analytics. As an estab­ lished North American service and parts or­ ganization, including domestic ink manufac­ turing, Durst allows a converter to make a more technical and financial decision to grow their business.

"It is very important that converters understand the business model and what it takes to be successful in digital production. W ith that in mind, we of­ fer all sorts of training to ensure our customers maximize digital production opportunities. This ranges from sales, marketing, and operator training right through to ink optimization. Our suc­ cess is our customers' success. From pre- to post-press, building digital vol­ umes is something we achieve in part­ nership with our customers who really appreciate our support and expertise," shares Slingerland.

EFI's expertise in industrial digital printing, its broad install base of single­ pass equipment, and its history of in­ novation make it an ideal consultative technology provider for converters mak­ ing the move to digital corrugated pack­ aging production.

"Corrugated converters/printers have already embarked on the journey to adopt digital solutions. We believe that if a converter sees the business opportunity enabled by this new technology, and, at

industrialprintmagazine.com

the same time, is realistic about the in­ vestments it requires-in terms of adjust­ ing workflows and managing print loads in a different way, but also looking and testing new applications-this will help tremendously in the decision making pro­ cess," explains Serrano.

HP partners closely with brands to help them understand the possibilities with digital print. It works directly with converters to analyze their production and evaluate the overall cost and time reduction, which can later be turned into increased capacity.

Personally, Shorer believes that for more to embrace single-pass digital printing, it is a "combination of brand de­ mands and the understanding that the fi­ nancial model should be calculated end to end and not just compared ink cost to ink cost. What we often hear is that 'digital ink is too expensive compared to flexographic inks.' This is indeed a true statement, however comparing end-toend costs, including plates, warehouse, waste, water, and labor shows that digi­ tal has an advantage over traditional printing and not just in hundreds of cop­ ies, but in thousands."

Kento North America is "removing the cost barrier that has been a major drawback for so many by providing a hybrid solution, along with an open ink system," explains Kent. "Add to this up­ gradeability, rotary die cutting, and even two-sided print and many now realize that single pass no longer means only digital print."

Robotics in Play AI and robotics are used in manufac­ turing facilities of all types, and cor­ rugated converters/print shops are no exception. With large, heavy pallets pro­ cessed daily it seems only fitting that automated material handling powered • •

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by AI and/or robotics be­ come part of the process to keep pace with the speeds single-pass print­ ers reach. ''Automation is the driving force in making every aspect of digital production more effi­ cient and profitable­ with material handling being a big part of that.

No matter whether in printing or cutting/fin­ ishing, if there is any­ thing impeding the flow of materials that keeps your printer or cutter operating non-stop, you are not getting as much ROI as you should on your equipment. And naturally, the faster the 5 printer-with singlepass capabilities-the more likely it will create bottlenecks downstream," attests Beatrice Drury, marketing and communications manager, Zund Amer­ ica, Inc. Automation in material handling was once unattainable, according to Kent because of "cost and space require­ ments due to the custom requirement of pre-feeders. Few manufacturers offer a sheet size that works with standard pre­ feeders and stackers.''

However, as technology advances, larger runs are processed with digital print. "These higher run jobs now bring into the equation the need for more automation at the front and back end. Add

C O M PAN I ES M ENT I O N E D INFO# Company 111

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113

Elitron

112 114

115 116

EFI

the automation and this can be a game changer for many plants," explains Kent.

"Reducing human touch points is key," seconds Slingerland. Material handling devices like continuous feed­ ing and stacking systems must be auto­ mated, efficient, and accurate. "This is particularly important when industrial­ scale digital production involves huge amounts of separate jobs that all need to be processed and loaded for delivery to customers fast.''

Serrano agrees that "adding robot­ ics to feed materials into the printer or taking it out of the stacker for further processing is a vital step in the overall manufacturing process."

• P� See page 24 for more information.

Website

durstus.com efi.com

elitron.com

HP Inc.

ho.com

Zund America, Inc.

zund.com

Kento North America

kentodigitalprinting.com

June 2023 [ Industrial Print Magazine J 23

Increased Demand Single-pass digital printing for corru­ gated increases demand for automated material handling systems.

Caroline Bell, marketing coordina­ tor, Elitron, admits her organization has experienced increased demand for automation in relation to the growth in single-pass printing. "We now offer many different levels of automation, based upon individual production re­ quirements. Workflow can be upgraded as production levels increase and extra automation-loading, unloading, sheet turning-can be added as required." ''Absolutely," seconds Drury. This is why Ziind launched its dual-beam Q­ Line with BHS180 board handling au­ tomation, designed specifically for the corrugated market. With robotic board feeding and offloading/stacking sys­ tems, in conjunction with UNDERCAM scanning, the system is fully configured for largely unattended, pallet-to-pallet processing of six-foot stacks of printed corrugated board.

According to Slingerland, "the cor­ rugated market is volume driven and

high production output is standard."

Some of Durst's customers' plants are completely automated, with most of the material handling mechanisms inte­ grated directly into customer logistics.

"This ability to run larger job lengths converters will desire to add automation where it makes sense so the single-pass machine of choice needs to marry up to standard automation machinery, taking up as little space as possible;' shares Kent.

At Scale Converters/printers need to adopt auto­ mated material handling mechanisms at scale and ensure implementation is done both safely and effectively.

Most converters or printers have ad­ opted automation in other forms before.

"For those who do desire to add automa­ tion, they will do this as they have with other machines throughout their plant, assuming their single-pass machine has the right format size to support standard automation machinery," advises Kent.

Safety mechanisms like fences and light curtains enable secure environments and eliminate risks, says Slingerland.

"Elitron fully trains operators so that they can operate all of our systems. We naturally address safety issues during training and explain the safety systems in place to ensure the safety of all within the production site," shares Bell.

Another example, the new Ziind cut­ ting system. "The speed and scale of the Ziind Q-line with BHS180 necessitated developing a sophisticated safety sys­ tem with components ranging from light barriers/curtains to retractable glass shields preventing access to the working area-without obstructing the view, as well as safety fencing surrounding the load/offload areas," explains Drury.

Just the Beginning Single-pass digital printers and their au­ tomated material handling counterparts are increasingly necessary for corrugat­ ed converters and printers. They check all the boxes in terms of meeting packag­ ing trends and sustainability efforts. We are at the beginning of adoption, with manufacturers and industry leaders tak­ ing the helm to educate on the advantag­ es of these worthwhile technologies. /PM

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AD INDEX

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COMPANIES MENTIONED Company Canon Solutions America Durst US Durst US EFI Elitron

24 [lndustfia/ Print Magazine] June 2023

4 5

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100 111 112 113

Company Enercon Industries Corooration Enqineered Printinq Solutions Epson Eason America, Inc. HP Inc.

I INFO# 150 151

146 101 114

Zund America, Inc. Zund America, Inc.

Company lnkcuos lnkTec Kento North America Koenia & Bauer Kammann !US) Kornit Diqital

2 19

I INFO# 152 147 115

153 102

zund.com zund.com

Company

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LSINC Corooration Optimum Diqital USA SPG Prints Zund America, Inc. Zund America, Inc.

154 103 104 116 148

industrialprintmagazine.com

We expect continued growth in wa­ ter-based inks for digital textile printing.

Environmental Benefits Water-based textile pigment inks are known to help reduce energy as well as water consumption, particularly when pre- and post-treating fabrics compared to other digital textile print options. ''According to the World Bank, the tex­ tile industry is responsible for approxi­ mately 20 percent of industrial wastewa­ ter worldwide. Based on a recent study by the Fuluhashi Environmental Insti­ tute, it was found that digital printing textiles with pigment inks can reduce the water used by up to 96 percent ver­ sus dye-based alternatives," states Mark Krzywicki, product manager, Profession­ al Imaging, Epson America, Inc. Of the many ink sets involved in textile printing, Sharon Donovich, marketing

EPSON

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26 [ lndustfiaf Print Magazine J June 2023

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director, global events and customer success, Kornit Digital, says pigment ink sets, without doubt, present the smallest effect on the environment.

"Reactive, disperse, and acid inks are water- and energy-wasteful, while dye­ sublimation (dye-sub) printing throws away as many meters of paper as it prints on textiles. By comparison, con­ ventional pigment screen printing uses 50 percent less water, 30 percent less energy, and 35 percent less water pol­ lution than other ink sets."

Setting or fixating these inks only requires a dry heat fixation to cure the ink once printed-eliminating the use of steaming or washing seen in traditional methods. "Having this single-step solu­ tion eliminates the excessive use of water as a resource, as well as toxic waste water as a byproduct of production," explains Edward Knight, partner, Optimum Digital

l

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MonnaLi<.>8000

USA It also requires less power by re­ moving the need for other machinery.

If you add all of these factors together with the inherent benefits of digital print­ ing technologies, which do not require the production of large minimum order quantities to be competitively priced, the advantages increase. "Our customers print on demand, significantly reducing the chance that the fabric is thrown into a landfill-currently up to 60 percent in the apparel manufacturing supply chain," remarks Knight.

Donovich points out that Kornit's pig­ ment ink is free of pretreatments, steam­ ing, and washing, enabling lessened con­ sumption and waste. "In accordance with Environment Health & Safety policy we dispose of effluent at the cycle's end as hazardous material separately from the municipal system. Process water under­ goes a short softening cycle before use."

Versatility Further, recent developments of pigment inks for digital printing on textiles are changing the way the industry prints on synthetic, natural, and blended fabrics, according Taner Can Guven, partner, Optimum Digital USA. As an ink type, Donovich points out that pigment printing is versatile, be­ cause, unlike any other ink set, it can successfully print onto any fabric of any fiber composition using one process.

Donovich explains that pigment print­ ing relies upon the strength of an ink's binder to lock the pigment particle to the fabric, while other ink sets use tailored chemical bonds that only work with one fiber type or another. "It is therefore the only ink set that is effective across all known fabric and fiber types."

Application Options Water-based pigment textile printing serves a range of applications, from ap­ parel to decor. The technology is being adopted by textile print service provid­ ers (PSPs), rotary screen printers in a

industrialprintmagazine.com

hybrid print envi­ ronment, as well as PSPs serving the sign and dis3 play market.

Durst US cus­ tomers pigment print onto textiles to produce uphol­ stery, window dressings, table and bed linens, apparel, and wallpaper, accord­ ing to Mike Syverson, textile manager, North America, Durst US. "We see most customers using Mon­ na Lisa GENESTA pigment ink printers today focused on the home decor and craft markets," agrees Krzywicki. "How­ ever, there is an increased use in the fashion market as more designers and customers are looking for technology so­ lutions to reduce water use."

Can Guven and Knight predict ap­ parel manufacturing as a large growth area. "Customers previously limited to a single type of fabric-like polyester-are now using our machines to produce on a wider range of fabric."

For example, Optimum Digital has customers using eco-pigment that range from women's apparel, baby products, sportswear, leisure wear, and pajamas. "The home decor space is also increasing with the ability for custom­ ized upholstery and interior designs on natural linens and cottons, albeit at a slower rate."

1. Kornit's Presto MAX is a direct-to-fabric solution.

2. Epson launched the Manna Lisa 8000 in 2022, an industrial direct-to-fabric printer for the North Ameri­ can market. 3. In 2022 Optimum Digital debuted the Nirvana Belt eco-pigment series, an industrial one­ step direct-to-fabric printing solution without need for pre- or post-treatment, which is now available in North America through its Atlanta, GA offices.

COMPANIES MENTIONED INFO# Company

"The adoption of water-based pig­ ment inks in textile printing is largely affected by the way the textile industry operates," explains de Brouwer. "When looking at the entire textile chain, one can conclude that fashion brands have a lot of power and are driving changes also related to sustainability. Sustain­ ability is considered an important factor in the whole value chain. Just look at the fact that several global brands have ap­ pointed a chief sustainability officer in their boardrooms."

A variety of customers are interested in pigment ink printing technology due to the comparatively simple workflow when compared to dye-based inks, along with the aforementioned water savings benefits, offers Krzywicki.

The Fabric Component When printing to textiles, the fabric itself is a primary consideration.

For water-based pigment printing pro­ cesses, a key benefit of pigment printing is substrate flexibility. "Using pigment ink you can print on an array of fabric types, including blended fabrics. At Epson, we have designated Solution Centers around the globe to help customers test new fabrics to evaluate print quality and performance," shares Krzywicki.

Donovich also stresses the process' versatility when it comes to the range of fabrics it can successfully print onto.

- P� See page 24 for more information.

Website

100

Durst US

durstus.com

101

Epson America, Inc.

epson.com/usa

102

Kornit Digital

kornit.com

103

Optimum Digital USA

optimumdigitalusa.com

SPG Prints

soaorints.com

104

industrialprtntmagazine.com

"Unlike any other ink set it can success­ fully print onto any fabric, of any fiber com­ position, using one process;' she explains.

"Generally, we see most companies printing pigment on natural fabrics like cotton, linen, and wool, although it is possible to print with pigments on oth­ er materials such as polyester, silk, and acrylics," says Syverson.

Can Guven and Knight see the most success with cotton and cotton blends, and state that linen also works very well.

"The great thing about pigment-based inks is the versatility and high quality across a wide selection of fabrics."

De Brouwer adds that fabric com­ patibility in essence is very wide, but influenced by the pretreatment used.

"Our experience is that in today's in­ dustrial textile printing environment pigment ink is mainly used with poly­ cotton fabric. In a lesser degree also 100 percent cotton for garment deco­ ration is utilized."

She admits that pigment inks are not yet suitable for use with silk. ''Also, the ink lies on top of the substrate and does not penetrate the whole fabric. This means pigment ink cannot be used in two-sided applications such as scarves."

Expanding Options The move to pigment ink printing, versus dye, is an area to watch when it comes to digital textile printing. We expect the expansion of capabilities to expand and adapt to the modern needs of today's consumers.

"The current range of fabrics to print with pigment-based inks is already the most varied in the digital printing space and I believe it will continue to grow," concludes Can Guven. /PM

June 2023 [ Industrial Print Magazine J 27