Olivia Cahoon

Built for EP

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By Olivia Cahoon

A variety of media solutions are available to help print providers expand product offerings. In electrophotographic (EP) and liquid electrophotographic (LEP) processes, synthetic media is an option. These substrates provide high levels of durability, often without the need for lamination.

Traditionally, media composed of plastics and other inorganic materials were not well suited for EP printing due to high fusing temperatures and melting risks. While a fairly mature technology, vendors in the space continue to offer advanced toners and hardware to reduce the amount of heat required in the fusing process. Meanwhile, new media formulations are designed to withstand higher temperatures. These synthetic substrates enable print providers to offer digitally printed output with qualities like tear-, stain-, and water-resistance.

Above: PPG TESLIN is a high-performance synthetic paper that stands up to water, chemicals, and scuffing.

Synthetic Media
Synthetic media solutions compatible with EP/LEP production presses differ by top coating, base film, and construction. Vinyl, polypropylene, and polyester are among the most common synthetic substrates. Each product offers advantages in terms of flexibility, durability, and finishing.

Polypropylene is a commonly requested synthetic media option for EP printing. These films don’t release the melting plastic odor commonly associated with vinyl. “Polypropylene films have come a long way in durability, which mirrors the expectations of most of the dry toners,” shares Brian Ayers, market development specialist, FLEXcon.

Synthetic papers are resistant to water, chemicals, and tearing—providing durability to almost any application, offers Mellissa Campbell, marketing coordinator, Masterpiece Graphix. “Easy to convert, synthetic paper can be perforated, laser die cut, scored, folded, and punched.”

Polyester is another popular synthetic selection due to its performance characteristics and press compatibility. “Heat stability gives polyester great on-press performance and distortion resistance while making it the most durable of all polys for in-field use,” comments Craig Surette, business development director, dry toner market, GPA. It provides resistance to tearing, stains, and weathering.

Compatible with a variety of surfaces, repositionable vinyl is a peel-and-stick substrate that does not rip, peel, or wrinkle and can be used indoors or outdoors. Rigid vinyl PVC is also designed for EP/LEP production equipment, which Campbell says offers excellent durability, UV resistance, rigidity, and low flammability.

While a variety of synthetic media options are available for digital printing, there are limitations. “It is broadly accepted that you can’t run just any synthetic through any digital press. You must use a media compatible with your print engine,” explains Fabrizio Mandingorra, PPG labels and print segment manager, Teslin Substrate Products.

One key factor is the media’s heat stability. Certain substrates like polyester run as high as 350 degrees Fahrenheit, while others like polypropylene and high-density polyethylene can soften at 220 degrees Fahrenheit. “You don’t want to chance damaging your machine and possibly voiding the equipment warranty,” cautions Mandingorra.

EP Solutions Advance
Media options for EP/LEP printing are limited due to high fusing temperatures, static buildup, and few available sizes. To widen the compatibility of synthetic media, vendors have advanced media formulations, top coatings, and print engines.

In EP printing, the fusing process requires heat and pressure to bond the toner particles to the media. While thermally stable base films and top coatings enable a broader synthetic offering, advancements are also essential to expanding media compatibility. “The prevalence of digital synthetics in the market enables OEMs to think about synthetics when developing new digital presses to bring to market,” says Joe Schember, production manager, digital specialty & paper, Mohawk Paper.

To improve the fusing process, OEM printer manufacturers significantly reduce the amount of heat required to fuse the dry toner to the synthetic media’s surface. “This has allowed for the expansion of more polyolefins to be used with dry toner technology, such as polypropylenes, which traditionally would have melted to the fuser rollers,” offers Ayers.

According to Surette, fusing temperatures for all EP engines are well above 300 degrees Fahrenheit and some continue to fuse at close to 400 degrees Fahrenheit. Even at lower temperatures, the risk of distortion or melting exists if the wrong synthetic substrate is chosen. “Putting diesel in a jet engine doesn’t work, the same way that putting an offset synthetic in a dry toner press will fail. The chemistry is wrong,” he offers.

In addition, certain technologies prepare synthetic media for efficient printing in terms of adhesion and print surface. For example, Kernow recently released its new Cobalt Coating Technology, developed to further expand the capabilities of synthetics specifically for HP Indigo presses. By using this new formula, Dan Lawellin, director, business development, Kernow North America, says Kernow has optimized a nearly unlimited range of synthetics. “With the Cobalt Coating, Kernow is able to take anything—rigid vinyl, polyester, polypropylene, even specialty films—and optimize them for the HP Indigo press.”

Overall, synthetic media progression allows for greater basis weight and caliper, larger sized sheets, and duplex capability with higher weight sheets, says Scott Harman, director of digital products, Appvion, Inc.

Applications Broaden
Media formulation advancements allow for more applications to be printed with synthetic media on EP/LEP devices.

This includes previously laminated applications and those requiring a substrate that is durable, waterproof, tear resistant, and UV stable, says Al Grant, director of sales, marketing, and distribution, Fusion Digital Paper. In the case of outdoor books and manuals, he believes Fusion’s Soft Polyester media offers all of these attributes including stain-resistance and static-free runability on digital copiers’ feeding/receiving ends and during print finishing operations such as jogging, stacking, cutting, punching, and perforating.

Menus benefit from digital synthetic media. According to Surette, they are often requested in short runs with multiple copy changes, which aligns with the flexibility of digital print and the efficiency and durability of synthetic print media.

Pressure-sensitive synthetics are also suited for labels, bumper stickers, name tags, and calendars. They are commonly used for outdoor applications and offer removable or permanent adhesion. “From counter tops to cooler windows, and restaurant tabletops to floors, pressure-sensitive synthetics deliver vibrant graphics, durability, and adhesive options for a range of needs,” adds Surette.

In retail, grocery, and hospitality industries, there is a movement towards signage in any and every location. “In-store graphics are up more than 50 percent from ten years ago, reinforcing that retailers understand that any flat surface is now a consumer communication point, and they’re using it to their advantage,” offers Surette.

Other applications ideal for synthetic media and EP printing include award ribbons, badges, freezer signage, magnets, manuals, maps, outdoor signage, point of purchase (POP), posters, stickers, wall signage, and window clings.

Efficient & Durable
Printing to EP/LEP-compatible synthetic media allows for durable output in a variety of calipers and thicknesses without the need for lamination or reinforcement. Print providers can spend a lot of time post print trying to increase material durability. After laminating, Lawellin says printers still run the risk of moisture seeping in or the sheets becoming damaged. “With synthetics, you get a printed piece that is inherently waterproof and tear resistant.”

Synthetic media options are selected for their longevity and the ability to withstand harsh environments. The level of durability ranges among synthetic substrates but typically stands up to moisture, wear, and even chemical exposure, says Mandingorra. Improved durability shortens production time and offers clients a higher value, more profitable product.

Added durability also allows the product to withstand a longer period of time. Due to the longer lifecycle of synthetic-based solutions versus paper-based products, Campbell says reprints are less frequently required. “Plastic substrates are less expensive than laminating paper and often result in faster turnaround times since the printer does not need to outsource lamination,” she shares.

The combination of available synthetic media options and the benefits of digital print open new opportunities for value-added applications.

For example, Grant says Fusion offers Fusion Digital Satin Fabric, a polyester waterproof and tear resistant fabric that is top coated for digital printing. One of the main applications for this product is private label sewable mattress labels. This application is traditionally offset printed, which Grant says has long lead times and requires large volumes to be cost effective. With Fusion’s EP-compatible synthetic fabric, customers can print as many labels as they need, when they need them. “Once printed, the labels can be sewn into the mattress for a beautiful, durable sewn in label,” he adds.

In addition to shorter runs, Surette believes digital synthetics are attractive due to their contemporary and clean appearance. “Synthetics are very different from the dated, frequently split or dog-eared waffle house menu look of laminated paper. They are efficient, on demand, and contemporary.”

“Reduction in overall volumes of printed materials and increased personalization and/or lower print jobs means the printer offers a full and professional solution to its customers with a more creative targeted message. These materials allow them to enter markets they previously could not,” says Simon Warren, head of sales marketing, Print On Group/Folex.

Disadvantages
While synthetic media offers high durability and shorter run lengths and times, there are disadvantages including higher upfront costs, a misunderstanding of synthetic types, and equipment challenges.

Synthetic media is typically more expensive than traditional wood-pulp based paper. However, from an overall expense point of view, synthetic media saves time and money by eliminating the need for varnishing and laminating. One disadvantage in a comparison against traditional paper would be cost. “But clients should be offered the right material type for the job, and cost savings can already be shown in production steps,” says Warren.

Mandingorra says one complaint is that some synthetic media builds up excessive static charge during EP printing, which decreases throughput, degrades print quality, and causes damage to equipment or harms operators. However, select synthetic media is designed to dissipate static, eliminating throughput and print quality issues, allowing printers to avoid jams and ghosting from print artifacts.

Many users also shy away from the use of synthetic materials because they don’t consider each option’s different characteristics, advantages, and disadvantages. “It’s more than just picking up a synthetic and running it. Some films crack easily if folded, but will handle outdoor weather well. Others may be extremely flexible and easy to use, but can’t handle the chemicals required by the end user,” explains Lawellin.

Often, customers that have had bad experiences with synthetics usually didn’t receive help, or misunderstood which synthetic best fits their application.

Challenges with EP-compatible synthetic media also derive from digital printing equipment. To avoid complications, Grant suggests print providers question if their equipment can handle the adjustments necessary to print a synthetic substrate, especially the heavier gsm sheets. It’s also important that the device achieves proper toner adhesion and print fidelity.

Trends
Increasing demands for digital synthetic media results in a variety of new materials for durable, on demand applications. With a range of synthetic materials now available, Mandingorra believes printers and label converters are inspired to offer more functional solutions.

One application driving the synthetic market is the adoption of the Global Harmonization System (GHS). The GHS standardizes and harmonizes the classification and labeling of chemicals. Compliancy requires specific information be printed in color, which Mandingorra believes has dramatically increased the need for durable labels certified to BS5609 with on demand color digital printers.

There is also a need for a broader range of sizes and colors of synthetic substrates. For example, Schember says thicker materials between 14 and 80 mils are becoming popular, as well as synthetic materials with different colors and finishes. More OEM technology now offers specialty toners such as white, metallic, and fluorescent in addition to CMYK, color products, and digital embellishments for dramatic effects.

Warren points to an increasing development of customers that expect high reliability when printing synthetics, especially with increasing press performance and speeds. “They have a job to print under a deadline and it must work before, during, and after printing, and then the required finishing,” he offers. “We see a lot of choice in the market, but customers are keen to choose a material at the right price level, but that must also meet the performance criteria.”

Considerations
Before selecting a synthetic media for EP/LEP printing, print providers should consider their equipment and media selection to ensure overall compatibility. This includes selecting a proper media supplier and communicating effectively with clients.

Print providers should confirm that the selected synthetic is specifically supported by their EP device. “It’s not uncommon to see someone choose a material not specifically designed for the type of EP/LEP device they are using and as a result, they see ink/toner failures on the press,” shares Lawellin.

Consider the application. While a polypropylene makes a great booklet due to its softer feel, it may lack the rigidity to work as well in an application where a POP sign needs to stand upright on its own. Other applications may require synthetics to uphold certain chemicals, handle a large number of creases, or be thermoformed into shape, offers Lawellin.

To fully understand the end use application prior to selecting the film, Ayers suggests print providers conduct fit-for-use testing under actual application conditions. “For instance, there may be durability requirements that need to be met such as UV exposure, chemical resistance, abrasion resistance, or some other unique specification.”

Achieving the best performance from synthetic materials also depends on the media supplier. According to Campbell, print providers should select a supplier that uses thorough testing, pristine clean materials, corona treating, and professional drying to develop dependable digital media.

Corona treatment alters the surface energy of printed pieces to improve adhesion. “Corona treating can be effective on many materials in achieving better adhesion of the digital coating to the material,” says Campbell.

Profitable Print
Digital synthetic media reduces the need for lamination while providing clients with a durable product. While heat stability and environmental implications are a concern for this type of media, new formulations and advancements to EP devices improve the use of digital synthetics for a variety of applications from credit cards and identification tags to menus and in-store signage. dps

Sep2018, DPS Magazine

Coating
Digital Print
Priming

Primed for Performance & Coated for Effect

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By Cassandra Balentine

The quality and performance of digital print technologies improve with the help of pre- and post-printing options in the form of primers and coatings. A variety of primers are available to enable proper adhesion between a substrate and ink or toner. Coatings are applied post print and can be both decorative—high gloss, matte, satin; and functional—low curl, low migration, and can also offer a tactile effect—pearlescent.

Both primers and coatings play an essential role in the digital print production workflow. “Without them, the substrates available to print on would be limited and the protection and functionality of your printed material would be greatly reduced,” shares Thomas Hayes, president, Kompac.

Above: Kompac offers a range of finishing options with a complete line of UV, aqueous, and specialty coatings and primers.

Primers and Coatings
Primers and coatings play different functions in the digital print process. Primers provide a better surface for ink adhesion and drying, and enable print quality. Coatings protect the ink and substrate, as well as add effects post print.

“In the past, priming and coating was relatively simple. However, the shift towards digital print technology and inkjet printing has created new challenges because coatings and primers are printer and substrate dependent. As a result, print producers are always looking for new solutions to everyday problems,” says Hayes.

He explains that this began with the HP Indigo, which required primed substrates for both papers and plastics to achieve the best quality. With the industry shift toward digital technology, companies like Canon, Konica Minolta, Ricoh, Xerox, and Xeikon now have comparable digital presses, each with their own individual toner and ink print systems. The same is true with inkjet. “As a result, coating manufacturers have come up with new coatings that adhere to both pre- and post-finished products to provide customers with excellent quality and consistency,” he shares. The process starts with the printer and is fueled by what the customer wants to produce. In some cases, customers want to reduce total cost by priming their own materials; others want to apply a high-gloss, UV flood coating to protect their printed output; and in other cases, features such as spot coatings are used to enhance the aesthetic value.

Jan Denies, marketing manager, specialty printing, Michelman, points out that together, primers and coatings offer increased resistance to printed material, including water, chemical, scratch, and thermal resistance as well as prevention of color fading. “Typically primers help improve adhesion to the substrate and print quality. However, it really depends on the substrate and the technology you print with if you utilize coatings, primers, or both. For example, if you print with HP Indigo, you will utilize primers for improved adhesion. When printing with UV inkjet on paper, your technology will need to provide both improved adhesion and print quality. The primer improves hold out, reduces bleed and mottle, and makes colors more vibrant.”

“For narrow format, the print house may not realize the heavy lifting done by the primer/coater as the substrate is prepared for digital print prior to entering their facility,” shares Kelly Lawrence, global market manager, digital print enhancers, the Lubrizol Corporation, a Berkshire Hathaway Company.

Digital print is a system of machinery, chemistry, and software that requires collaboration among the parties involved to enable a quality print with a seamless production process. “If further durability is required for the application, an overprint varnish may provide greater durability for spot finishes such as high-gloss areas,” adds Lawrence.

John P. Vogel, president, Chesapeake Digital Consultants and consultant for Alliance Technology Corporation (ATC), says primers are required for some digital printers to provide adhesion to stock, achieve the required sharp printing, seal the sheet to provide a consistent look on the printed piece, and provide proper surface tension for 3D structures.

Topcoats are an integral part of digital printing, regardless of the print method used. Melissa Walsh, product manager, digital media, Acucote, points out that there are materials that will print without a topcoat across a variety of print technologies. Specifically for labels, she suggests running topcoated materials designed for the specific print system to enhance the image quality.

On the other end, some coatings are applied post printing. They play an essential role in delivering functionality, protection, workflow, and aesthetics to digital production printing—particularly in the digital package printing market, says Heather Buchholz, marketing program manager, Sun Chemical.

Coatings add protection to printed materials. “Digital inks may lack good rub, scratch, and water resistance as well as other environmental issues required by the finished product,” says Vogel. Coatings are also used to add features like high gloss, matte, and semi-gloss. Special effects like soft touch, strike through, and pearlescent are provided with UV coatings.

Application of Primers and Coatings
Depending on the specific environment, the application of primers and coatings vary. Primers are applied prior to printing—either by the print provider, mill, or inline—a variety of coating units, including blanket, gravure, flexography, screen, inkjet, anilox roll, and roller coating systems.

“These coater types may be applied in a typical offset press, a standalone unit, or part of an entire finishing system,” says Matt Apke, product manager, coatings, Kustom Group. He explains that aqueous coatings are dried via hot air and infrared (IR), while energy curable materials use exposure to UV or LED light and electron beam technology to cure.

Denies says Michelman’s water-based coatings are applied with gravure or flexography and need to be dried before printing.

Primers are applied inline or offline, and press owners can choose to do the priming themselves. “Typically, printers apply primers inline while paper mills, substrate vendors, manufacturers, and converters apply primers offline,” offers Denies.

Several factors impact curing and drying—is the coating water-, solvent-, or UV-based? What is the coat weight? What is the substrate? “A longer dryer system with lower temperatures may be used to cure a coating on a BOPP film versus an absorbent substrate that can withstand higher temperatures such as corrugate board,” states Lawrence.

The application of coatings requires a skilled operator with knowledge of coating equipment. “Like any equipment, regular maintenance is required to yield good product performance and production rates. The manufacturing footprint should also be assessed. Total cost of ownership is a consideration prior to any capital investment,” says Lawrence.

Advantages and Challenges
Primers provide more flexibility in terms of the substrates that are able to run through a digital press.

“Printers with offset presses have a large stock of offset papers. When they purchase digital equipment, they utilize offset papers and other substrates because of access to inline priming,” says Denies.

Apke agrees, noting that primers provide a better print surface for improved graphic quality and adhesion. “Primers can also be used to improve drying capabilities of certain inks,” he adds.

Both primers and coatings are used to improve functionality and quality, which allows for printing higher end applications. “Priming and coating technology allow for higher levels of water, thermal, mechanical, and chemical resistance that allow printers to enter into markets they would not otherwise be able to,” shares Denies.

These solutions enhance overall print performance with improved color pop and durability by enabling ink to anchor onto the substrate. “The higher performance required the more critical the coating/primer,” says Lawrence.

Coatings help deliver the required surface. “We are starting to see smart OEM initiatives that rely on coating strategies designed to expand printing applications by enhancing interaction between primers, inks, and overprints. These strategies should deliver better matched systems, contributing to better performance and higher productivity,” says Buchholz.

Coatings can also control the finish—gloss versus matte or clear versus opaque, offers Lawrence.

One challenge is finding a product to satisfy all OEMs within a print category. There is no one size fits all. “The media that passes and is approved by one OEM may need adjustments by another OEM—even though both presses are of the same print technology,” offers Walsh.

The challenges around primers revolve around adhesion to multiple substrates, use of multiple formulations and chemistries, and limited success in providing a solution for aqueous inkjet printing. Also, paper primers may not be the same for plastic.

Apke explains that HP Indigo ElectroInks require a primer that is only available in aqueous chemistries, limiting drying and application capabilities. “Aqueous inkjet relies heavily on absorption and air flow for drying and print quality, making its use on top of non-porous substrates or energy-curable coatings extremely challenging.”

Walsh adds that when a product services multiple print methods, it is not always economical. “As a supplier, the number of topcoat vendors remains limited. Working with these vendors to formulate new topcoats takes time. It is also a developmental process to ensure the proper coat weights are applied and efficient drying takes place,” says Walsh.

Apke says coatings must overcome surface tension dynamics created by surfactants in inkjet inks, carrier solvents in wet toner inks, and drum release fluids of dry toner inks. “These materials create low surface energies that are difficult to wet out and adhere to. Unique chemistries and higher cost materials are used to supply effective coatings. Certain substrates are challenging—especially extremely porous materials that require coatings with higher viscosities and other unique properties to effectively protect and dry.”

Additionally, some digital primers have a limited shelf life for the stock. “Care must be taken to rotate your stock and use it in a timely fashion. That is why some companies prefer inline priming or priming offline, in house, as needed. Others have chosen to purchase pre-primed stock from a paper converter and order as needed, but stock selection could be limited,” says Vogel.

He adds that not all UV coatings lay well over every digital ink. “Some digital inks require a primer over the print to accept the UV top coating. Others could require an IR unit or corona treatment unit to change the surface tension of the digital ink to accept the UV top coatings.”

He adds that there is a difference between top coating inline versus offline.

Performance-Driven Advancements
As digital printing technology continues to gain acceptance in the overall industry, the bar is heightened for quality and performance expectations.

Walsh says as OEMs continue to advance presses and inks, it is important to be at the forefront of product launches to ensure the current solution is still viable.

The role of primers and coatings changes with the evolution of inks, toners, media, and equipment. “It’s based primarily on the outcome of requalification. With this being a Labelexpo year, I suspect media suppliers will be working diligently to qualify substrates on the latest press innovations and new ink technologies,” she says.

As end user driven performance expectations continue to rise, primers and coatings are asked to bridge the gap between ink and substrate performance, comments Lawrence.

The increasing functionalities of primers, coatings, and inks expand the applications of the printing and packaging industry. “Technology allows for inserting some primer functionality into ink, but it will make ink more expensive with potentially higher maintenance costs. This brings the balance of cost and functionality to the forefront. Primers play a more important role as presses are utilized for more creative and demanding applications such as labels for personal care products, edible oils, and household chemicals. There will always be a need for primers because they allow the ink and substrate to work together for higher quality output, especially as the industry demands more from its presses and moves from paper substrates to synthetic substrates,” says Denies.

Vogel believes the role of primers and coatings is changing as printing companies seek to transition more print from analog to digital. “The challenge for paper, coating manufacturers, and coater manufacturers is that the digital equipment manufacturer offers solutions that differ from one another—digital inks, printheads, and software vary greatly. Some companies sell their inkjet technology to more than one digital equipment manufacturer. For the printer, choosing the correct digital printer for today’s work and tomorrow’s can be confusing,” he admits.

Primed and Coated
The need for a primer is dependent on a variety of factors within a digital print setting. Primers and top coats are used to optimize compatibility between certain media and equipment, improving adhesion for better quality and durability.

After a print is imposed, coatings add protection, vibrancy, and special effects, adding value to the application.

Finding the right combination of primers, coatings, and media requires a knowledgeable staff and clear communications with the press manufacturer and media supplier. dps

Sep2018, DPS Magazine

Coating
Digital Print
Priming

More Jobs for Inkjet

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By Melissa Donovan

Cutsheet inkjet technology is closing the gap between cutsheet electrophotographic (EP) capabilities and continuous inkjet. Customers request quality printed products. Advancements in printheads, media compatibility, and ink sets all play a role in cutsheet inkjet’s ability to provide this. Technology has changed to the point where a number of applications are now possible on these machines. This includes high-end direct mail pieces, transactional statements, books, commercial printing, and some forms of packaging.

Above: The Fujifilm J Press 720S delivers offset-quality brand work like pocket folders.

A Key Tool
United Mail got its start in 1980. Today its two locations—Louisville, KY and Cincinnati, OH—employ 350 staff members. The company services the full communications lifecycle—from data management to print production all the way to presort. Its customers include healthcare providers, insurance companies, fast casual eateries, government contract work, marketing and advertising agencies, higher education, retail, and financial services.

In 2017, United Mail purchased its first color cutsheet inkjet device, an Océ VarioPrint i300 from Canon U.S.A., Inc. Prior to that, it offered monochrome variable inkjet printing as well as roll-to-roll laser printing, but found clients requesting more color for this type of work. “It became a challenge with existing technologies and outsourcing didn’t seem right to us. So we got to a tipping point in customer demand for color and cutsheet inkjet was the solution,” explains Dayna Neumann, EVP, business development, United Mail.

The press’ ease of use, size, reliability, and variability meets all of United Mail’s requirements. In addition, the Océ VarioPrint i300 satisfies the needs of its customers. Everything and anything is run through the printer, according to Neumann. This includes postcards, self mailers, brochures, and statement work.

There is a high level of variability when it comes to projects. Different quantity breaks for each job are common. With the printer, United Mail has grown its customers’ job volumes as well. It takes on larger runs while offering quality output. The company averages 4,200,000 impressions per month and 1,050,000 impressions per week.

Neumann points out that the company finds the color quality of the Canon Océ VarioPrint i300 to be particularly advantageous. “There is a big difference in color inkjet today. Gone are the days of banding and saying no when a client wants a specific color. The Océ VarioPrint i300 is a workhorse and can run anything and run it well,” she continues.

With United Mail equipped to handle all aspects of a customer’s communication stream, the Océ VarioPrint i300 is another tool that allows the company to take a project from idea to printed piece.

Dynamic and Flexible
Founded in 1974, OBRIEN Insurance Solutions serves insurance clients out of Bartlett, IL. 95 percent of the applications produced are regulatory documents, premium notices, cancellations, endorsements, declarations, and polices. According to Mike Mulcahy, COO, OBRIEN, the company’s goal is to act as an extension of its clients’ businesses. It works as the middleman between the insurance company and IT, handling the data and presenting it in a professional way.

In 1995 its first monochrome digital press was purchased. The addition of digital allowed OBRIEN to transition from static to variable communications. Around 2016, the company decided to bring color inkjet into its print offerings. This was driven by a client who was looking for more flexibility and dynamic color—something not possible with its existing portfolio of printers, shares Pete Mier, director of business development, OBRIEN.

It turned to RISO, Inc., specifically the ComColor X1 9150 and ComColor GD 9630 models for speed, quality, small footprint, and reliability. “We have tight SLAs with our clients and cannot afford to be down. The RISOs provide the speed and reliability for us to meet and exceed client expectations,” says Mulcahy.

Both printers are similar from a production perspective. Mier explains that a lot of the work OBRIEN completes is repetitive, meaning one job has many drops throughout the year so after the first drop, the production team knows the best printer to send it to and the ideal paper type. Many files are handled on a daily basis—and quickly. For example, the company may receive files at night and by 5:00 p.m. the next day they are out the door.

Despite advancements in printheads, media compatibility, and ink sets to enable higher quality output, there are still challenges. For one, choosing the best substrate for each job presents learning curves, as print quality varies. Mulcahy admits there is a lot of trial and error when it comes to deciding on the right stock. OBRIEN works with Boise paper and has its own branded stock that has been tested and works best in its production environment.

Also, says Mulcahy, ripping the file on the front end, paper jams, and jobs cutting out in the middle of the run are all issues that OBRIEN has worked closely with Impact Networking—the dealer it purchased the RISOs through—to overcome. If the printers go down, Impact is there in under an hour. This type of response allows the OBRIEN team to focus on production and not technical maintenance.

Cutsheet inkjet still has limitations and it’s made OBRIEN more aware of the importance of educating clients. For example, flooding pages with ink is expensive so certain applications can be costly and that may be difficult for a first time user of inkjet to understand. The same can be said when it comes to designing with a bleed. Many clients come from an offset background, explains Mier, so they need to be taught that offset to inkjet isn’t a literal one-to-one replication.

“This points to our business model. We talk to the owner at the insurance company and they have a small print shop in house. It’s hard for them to keep up with printing and the technical aspect. We take that off of their plate and leverage our expertise,” says Mulcahy.

Quality Advancements
United Mail and OBRIEN’s experiences with cutsheet inkjet are common. Largely familiar with offset, or EP, most print providers have kept a watchful eye on inkjet’s advancements in quality over the years. Quality is achieved through a combination of components. This includes enhancements to printheads, media handling options that increase substrate compatibility, and ink sets.

“To achieve the quality level we see today requires the integration of cutting edge technologies—inks, screening algorithms, color management, printheads, and even the wavelength jetting technology the printheads use,” says Ed Pierce, product marketing manager, Fujifilm North America Corporation, Graphic Systems Division.

In particular, printheads have gone through physical changes. “Today’s Pagewide printheads have many more nozzles per inch than in the past. Not too long ago, 600 dpi printheads were state of the art. Newer manufacturing technologies have led to higher resolution printheads,” shares Gianluigi Rankin, director of product marketing, Memjet.

For example, Memjet’s current printheads feature a native resolution of 1,600 dpi. This resolution—when combined with much smaller drops than in the past—allows for a higher quality print with sharper text and smoother transitions in images that rival offset.

“As a general rule, inkjet print quality begins with the resolution of the printheads, but perhaps depends even more on the media and inks as well as color management and process controls on the press,” adds John Santoli, global product manager, Xerox Brenva HD Production Inkjet Press, Xerox Corporation.

Paper manufacturers represent an important group in the shift to inkjet. “The key is the brightness level of the paper. The brighter and whiter the paper, the better the image. And where we once needed a 32 lb. or heavier paper to keep inkjet from bleeding, today a 24 lb. works fine,” suggests Andre D’Urbano, director, dealer, sales and corporate marketing, RISO.

Sheri Jammallo, senior advisor, marketing, production print solutions, Canon Solutions America, agrees that media options have come a long way, allowing print providers to use offset uncoated, offset coated, inkjet treated, and inkjet coated papers.

“The advancement in quality comes with the wider substrate flexibility of UV LED inkjet. The ability to print on an expanded range of substrates beyond paper has allowed for a wider, achievable application base,” explains Scott Robertz, product manager, digital, Komori America.

And then there are the ink sets. “From its inception, inkjet has been notorious for bleeding into the paper it is printed on. The end result is crisp black turns into dark gray as the ink bled into the paper. Also, it made duplexing very challenging as the images from the front and back page would turn into a blur. There have been great advancements and much of it stems from the improved quality of ink,” explains D’Urbano.

At RISO, a resin similar to the compound found in nail polish or lacquer is added to the ink. This allows newer RISO inks to harden much faster than previous versions. Admittedly a balancing act, D’Urbano says this newest iteration reduces bleeding and improves image quality. In the future, he believes ink will bleed so little that it will resemble toner.

New Applications
With quality advancements, print providers are testing different applications with their cutsheet inkjet solutions. These include direct mail pieces, transactional statements, books, and packaging.

According to D’Urbano, jobs that were once monochrome now benefit from color. “The jobs that are being transferred from toner to inkjet are those jobs that are primarily monochrome in nature but where color is needed for a logo, header, or highlight. It is a business color, a splash color, a communications color for documents like bills, invoices, manuals, exams, course material, forms, numbered NCR, and other low coverage applications including envelopes,” he continues.

Applications that make the most sense for a cutsheet inkjet platform are generally printed on plain papers such as transactional statements, books, and manuals, as well as those that require a variety of finished sizes such as booklets and direct mail. “These applications are time sensitive and therefore produced in shorter runs and are designed using lower area coverage styling—making them an ideal candidate for the low run costs associated with inkjet,” shares Santoli.

Transactional printing is using cutsheet inkjet more frequently. “The overall print process is simplified. Instead of printing black text on pre-printed forms, the printers can print all content on white paper, reducing inventory costs and turnaround times. With these new solutions, printers can also expand services to color transpromotional printing as well as direct mail,” says Rankin.

High-end direct mail is another target for cutsheet inkjet. Pierce notes that historically, high-end brands requested top quality direct mail pieces, which required an offset device to produce the expected quality level. “Today, cutsheet inkjet’s quality level is easily met while the print provider see a profit due to the ability to address a run length that has been ever decreasing and also adding the variable and personalization factors,” he suggests.

“Sheetfed inkjet allows printers to switch easily between different substrates and produce vibrant color at affordable prices—so from postcards to catalogs or promotional materials, direct mail can certainly benefit from sheetfed inkjet,” agrees Jammallo.

Publishing is another area that benefits from cutsheet inkjet. “We are seeing books as a growing application. The affordability of inkjet and ability to run cost-effective shorter and variable runs on sheetfed inkjet makes this prime for book printing and one anticipated area of growth,” says Jammallo.

At Fujiiflm, there is specific interest from the folding carton segment of the industry. “This is driven by a couple of main influences. The short-run folding carton segment is growing. This is driven by SKU proliferation, local and regional product packaging, and boutique businesses needing short runs but also high quality and matching reprints, commerce as well as variable data, or personalized packaging. The growth is also due to the quality we can now deliver and the large color gamut that can be achieved with a four-color press,” shares Pierce.

More Jobs for Inkjet
Advancements in cutsheet inkjet technology mean more work for digital printers. The quality coming off of the latest cutsheet inkjet equipment today is miles away from what it once was—targeting new applications and markets.

Print providers such as United Mail and OBRIEN adopt cutsheet inkjet to enhance current customers’ print requests and ultimately grow their job volumes. For these print providers-—and many more like them—cutsheet inkjet is a positive addition to their existing digital workflow. dps

Sep2018, DPS Magazine

Cutsheet
Digital Print
Inkjet

Opposites Attract

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By Olivia Cahoon

Magnetic graphics are convenient and efficient applications well suited for vehicles, promotions, and novelty items. Magnet applications are often an add-on item for existing clients—enabling print providers to broaden their product offerings and add new revenue.

To produce custom magnets, print providers have the option to print directly to magnetic media, print to media that is then magnetized, or opt for magnetic-receptive media that doesn’t stick to metal, rather that magnets stick to it.

Above: A Xerox Color 800i helped Eri, PA-based McCarty Printing complete work for the committee to elect Joe Schember—custom car magnets with Mohawk Magnetic High Gloss polypropylene white energy 17 mil.

Decades of Print
Based in Erie, PA, McCarty Printing began as a commercial printer in 1916. As a privately held and locally owned corporation, the company has been under the same family ownership since 1954. The business started with eight employees operating in a 5,000 square foot workspace.

Through constant investment in the latest technology, McCarty Printing now operates as an advanced production plant that produces high-quality printing for catalogs, brochures, flyers, stationery, and advertising promotions.

Serving customers regionally, nationally, and internationally, the company offers offset and digital printing capabilities from its 50,000 square foot facility. With 75 employees, McCarty Printing utilizes a number of digital options to complement its offset business while providing customers with high quality, low-to-medium volume printed pieces.

“McCarty Printing can take a customer’s idea and design, proof, print, finish, and ship locally, nationally, or internationally,” says Mike Arnold, VP/sales, McCarty Printing.

Its sister company, Walco Label, produces safety labels and bar codes for manufacturing, safe-ink labels for food and beverage, shelf and sales labels for retail and promotion, and stickers and pressure-sensitive tapes for bottles, boxes, and cans.

In 2002, McCarty Printing started using digital print technology to address industry trends for short-run, full-color products. It utilized a Xerox Document Center 12.

Soon after, the company turned over its print production to digital for mailers, letters, envelopes, brochures, synthetic, dimensional, magnetic, pressure sensitive, and embedded applications. With this technology available in house, it expanded into several industries including advertising, medical, manufacturing, food and beverage, chemical, education, and banking.

Expanding Offerings
McCarty Printing outsourced its magnet work prior to investing in digital due to low demands. The company continued outsourcing its magnet applications until 2017 when a client requested custom car magnets as an add-on product.

While this offering is still a small percentage of the company’s overall work, it allows the print provider to tap into a new revenue stream and leverage its investment in digital printing.

The print provider produces magnet applications on the Xerox Color 800i Press with Xerox dry toner. The press handles production color printing with the ability to pre-configure specific application settings. It produces 80 pages per minute and handles sizes up to 13×19.2 inches with a maximum 55 gsm weight.

Arnold says the shop selected this press because it handles thick materials. “It is the only press that we have that can handle a thickness of 17 mil—the thickness of the magnet material.”

Currently, the print provider sources all of its magnet materials from the Mohawk Magnetic line, which offers unmagnetized media for ease of printing that are charged post-print with a variety of magnetizing equipment. The magnetic media line includes white stock options like high gloss, matte, semi-gloss, and paper in weights from 13 to 17 mil.

In addition to the Xerox Color 800i, the company uses several other digital printing presses including the Ricoh Pro C9110, Xerox Color C75 with EFI Fiery RIP, and Xerox Versant 180P.

With its digital lineup, McCarty Printing experiences all the benefits of digital printing including short runs and fast turnarounds. “Low runs are not outrageously expensive, we can print and deliver jobs in a short period of time, and we can add variable data at no additional cost,” comments Arnold.
Its magnet offering expanded to advertisements, envelope stuffers, calendars signage, and appointment reminders.

McCarty Printing’s bindery department offers a range of finishing capabilities including die cutting, scoring, perforating, folding, gluing, and padding. Blind embossing, foil stamping, foil embossing, debossing, shrink wrap, and custom labeling are also available in house.

An internal mailing department enables McCarty Printing to provide complete services for clients’ mailing needs. By integrating mailing with print production, the company offers convenience, quality control, and cost efficiency for all of its projects.

Promotional Magnets
In February 2017, McCarty Printing produced its first magnet job. The committee to elect Joe Schember, a local candidate running for mayor, approached the print provider for mailing campaign advertisements and soon after inquired about high-quality car magnets that matched the campaign’s brand standards.

At the time, the company didn’t offer any type of magnet offering and quickly looked to its digital equipment for the task. “The quantities fit digital run lengths and we believed our digital printing technology was capable of producing them,” says Arnold.

Because it was the first time printing with magnet materials, McCarty Printing partnered with Mohawk to keep production local and to test sample sheets prior to accepting the project. “The magnet needed to be strong enough to stay on a car and stand up to the elements for a period of time,” comments Arnold.

The print provider ran its sample tests on the Xerox Color 800i using Mohawk Magnetic High Gloss polypropylene white high energy 17 mil. Designed for use on automobiles, Arnold says Mohawk Magnetic High Gloss is easy to locally source. “Mohawk provided the technical support needed to help us through our first time working with the material, including the use of a hand magnetizer to charge the sheets post-production, and trimming.”

A hand magnetizer is a metal roller, somewhat like a paint roller, that emits high-intensity magnetic fields. It runs over the magnet’s backside to activate the material’s magnetic properties. “When it travels through the press, it isn’t magnetized yet or it would never travel through the machine without adhering to the metal parts,” explains Arnold.

With Mohawk’s magnetic media and the Xerox Color 800i Press, McCarty Printing produced 1,200 car magnets in two sizes—5×5 and 12×12 inches. For finishing, the magnets were guillotine trimmed with the 45-inch Polar Automatic Cutter and installed by end users.

The company experienced a small learning curve during the printing, finishing, and magnetizing of the magnets, but received the help and support needed from Mohawk and its in-house staff. As its first exposure to magnet materials, McCarty Printing successfully completed the order in one week.

“We gained some valuable experience on equipment capabilities and learned how we can offer this type of service for our clients,” offers Arnold.
The client won the election and was pleased with the quick turnaround and high-quality car magnets produced. According to Arnold, the committee was happy with how well the materials held up outdoors, especially without any post-print UV coating.

“It was cool to see our work around the city on car bumpers during the election season, and we like to think that this form of mobile advertising helped the candidate pull off the victory,” he offers.

Magnetic Print
Since its first magnet project, McCarty Printing has successfully completed several digitally printed magnet jobs including two more orders for the mayor. “It was an opportunity to keep the work produced locally, which was a goal of the client,” says Arnold.

The company continues to invest in the latest digital printing technology and expand its applications as new demands emerge. dps

Sep2018, DPS Magazine

Digital Print
Magnets

New Markets

by

By Olivia Cahoon

Wide format printing capabilities enable print providers to expand service offerings with a limited investment. These devices allow for a range of applications from banners to point of purchase (POP) displays. Depending on a printing businesses’ existing operations and clientele, a variety of solutions are available.

Above: Sesco-DSS of Fredericksburg, VA created real estate signage for Coldwell Banker Elite. The signs were produced with Palight Trimboard and printed on a Canon OceArizona 365 GT.

Reprographic Beginning
Established in 1971 in Fredericksburg, VA, Sesco-DSS started as a surveying and drafting equipment retailer. It offered supplies like drafting tables, grid sheets, and prism poles to industrial markets for construction and engineering.

In the 1980s, local demands for printing influenced the company to purchase its first printer from Océ and enter into reprography. With the addition of printing devices, it started offering blueprints and CAD drawings.

Today, it is provides surveying, drafting, design, construction, and wide format printing. With three locations in VA, Sesco-DSS maintains a close-knit group of 11 employees and produces over 500,000 square feet of print annually.

The print provider’s mission is to enhance the success of customers by providing quality products, extraordinary service, and a skilled, knowledgeable staff. Its services include large document copying, construction supplies, field equipment, drafting supplies, surveying supplies, and small and large format color printing.

At one point, Sesco-DSS produced $300,000 in blueprinting sales per month. While that number has decreased, the company still produces a monthly blueprinting average of 250,000 square feet. It primarily serves its local area but has also sold equipment and services around the U.S.

Going Digital
Over the years, the print provider added several new printers including digital devices like the Canon Océ ColorWave 600 and Canon Océ TDS860, as well as several of the Xerox 7500 models ,for high-quality color posters and basic banners.

The Océ TDS860 is often paired with bond paper, Mylar, and Océ E1 toner while the ColorWave 600 runs Tyvek, heavy weight bond paper, and Océ ColorWave Toner Pearls. The company uses a variety of software including Adobe Illustrator to design textual based images, Adobe Photoshop for advanced jobs, and ONYX RIP.

In 2012, Sarah Degen, VP, Sesco-DSS, took over full time and began to research the printing industry. “With my current paradigm, it seemed to be a dying business,” she reveals. Between 2013 and 2015, Degen obtained her MBA, which helped her look for trends and patterns in the current market. “I knew that we needed to enter a new area, I just wasn’t sure what that was yet.”

Degen proceeded cautiously with her search until settling on wide format with a vision of producing simple building plans and similar renderings. “I didn’t want to throw myself into something completely out of our vision as a wide format printing company,” she shares.

The print provider toyed with producing smaller, promotional-type products, but ultimately decided it would be difficult to compete. As blueprinting and CAD drawing sales began to decline, Sesco-DSS was determined to adapt.

In the Fall of 2017, the company’s Canon representative introduced them to the Océ Arizona 365 GT. “I felt that I had finally found what our next venture would be,” shares Degen. The Arizona 365 GT features an additional roll module and was installed in February 2018. It took a month to adjust to the press and for the employees to be properly trained. “Regardless of our stage in this process, Sesco-DSS has found a small niche to nestle.”

The Arizona 365 GT combines a flatbed printer design with an optional separate, dedicated roll-to-roll capability. Print speeds reach up to 377 square feet per hour with a maximum print width of 86.2 inches. With its wide format press, the company often uses Palight Trimboard products from Palram, scrim matte banner, peel off canvas, foam board, and Arizona 265 ink.

According to Degen, the company chose the Arizona 365 GT because Canon has been a part of its success for decades. “We know the products, we know the representatives, and we thought that this printer would be a good starter model for us.”

Initially, Sesco-DSS thought it would sell a lot of window cling products with its new, digital wide format printing capabilities. “We have had some success in that area, but the large site construction signs have been the real success market for us,” shares Degen.

The company currently produces a large amount of commercial real estate signs and banners for local real estate companies. To keep up with demand, it hired three employees since purchasing the Arizona 365 GT.

As a print provider that expanded into wide format, the biggest benefit for Sesco-DSS is that it already has an established set of base customers, some for over 30 years. “We established real relationships with these individuals and therefore, are able to sit down and talk about our new offerings,” comments Degen. Many of the company’s initial large format sales came from of its existing customer base.

Another benefit for Sesco-DSS is that it understands printers and the quality that its customers require. “We have always prided ourselves in being a high-quality CAD printer and transferred that mentality over to our new printing services.”

With its wide format offering, Sesco-DSS primarily serves architects, engineers, construction, and real estate industries. In May 2018, 25 percent of sales came from its new Arizona 365 GT.

Degen notices that customers are more attuned to shopping local if possible. “Most of my customers tell me that they prefer not to buy online, and they appreciate the effort and attention that a small, local company can bring them. I think the pendulum is swinging back into the small shop consumer mentality.”

Real Estate Promotions
In May 2018, repeat customer Coldwell Banker Elite approached Sesco-DSS for real estate signage. The client requested two large signs to attract the attention of potential clients without being too visually busy.

For this job, Sesco-DSS produced two 4×8 foot V-shaped signs using Palight Trimboard. “The product is extremely durable as it has a lifetime warranty of 25 years,” comments Degen. Palight Trimboard is available in a variety of thicknesses and widths including finishes in white, sand, and clay.

The signs were printed on the Arizona 365 GT, which Degen says lays and cures ink very well to the substrate. “We prefer to use this over Sintra board because we get a sturdier product that lasts much longer for our customers.”

The real estate signs were designed to meet the client’s specific needs including a custom logo and the preferred Coldwell Banker blue. No finishing was required. “Luckily, our printer has amazing curing properties, so we don’t need to add any additional finishing to the product. Once printed, it was ready to be installed,” shares Degen.

The signs were installed in a V-shaped pattern using white painted sign posts. During installation, the print provider experienced challenges due to the weight of the board. “These boards can be very heavy to lift and even more difficult to handle with wind,” offers Degen.

From job submittal to installation, it took Sesco-DSS five days to complete the real estate signage. Overall, it was a relatively large job for the print provider. The printer is at capacity when handling boards of 4×8 feet.

Coldwell Banker was satisfied with Sesco-DSS’ quick turnaround and the product’s rigidity. In the past, the client’s previous print provider printed on vinyl then laid the vinyl on an MDO board, which resulted in peeling. “Because we print straight onto the substrate there are no more peeling issues,” says Degen.

Expanded Products
Print providers looking to expand into new markets turn to wide format printers, as these devices offer new services and applications that expand existing work. As its wide format output continues to grow, Sesco-DSS plans to invest further and upgrade to the next model of the Arizona 365 GT. “Our scope is much wider, and we are trying to see how we can get involved in many facets of the wide format industry,” concludes Degen. dps

Sep2018, DPS Magazine

Digital Print
Wide Format