Olivia Cahoon

By Melissa Donovan

Converters, consumers, and packaging companies increasingly rely on dedicated digital label printers. The technology enables cost-effective, smaller volumes of labels, which are ideal for limited edition runs in a number of different product markets. Quality, cost, and ease of use are the biggest considerations for buyers when it comes to digital label presses. Challenges facing digital adoption include investment costs and hesitation in changing the way a business is run.

Above: Xeikon offers inkjet- and toner-based digital label presses.

Varying Stages of Progress
Segments implement technology at different phases based on their needs and awareness of trends. Where they are in the process—whether it be in the discovery phase, purchasing point, or physical integration—illustrates how up to speed a converter, consumer, or packaging company is on the benefits of digital presses used in label printing.

Converters are very attune to digital print. “The majority of converting companies recognize digital as a viable solution for short-run label production,” says Taylor Buckthorpe, director of sales and marketing, Colordyne Technologies, LLC.

Based on input from Epson America, Inc., more than 60 percent of large label converters already own a digital press. Most are looking to make an initial or even secondary purchase.

“These days, there is no label converter who is not questioning if they should go digital or not,” says Filip Weymans, VP global marketing, Xeikon. “The market is changing so much and their competition is/has been investing in digital print capacity, which makes it an even more competitive landscape.”

The degree to which converting companies embrace digital is really a function of markets served, niche applications, and areas of expertise. “When a converter is careful and diligent to factor in the uptime and availability that is possible with some digital presses, they then see there isn’t much of a difference between flexography and digital in run time or cost. This is especially true when prepress, plates, makeready, and waste are factored in,” explains Mark Schlimme, director of marketing, Screen Americas.

“The majority of label presses sold into label converting companies are digital,” say Brian Cleary, label segment category manager, HP Indigo, and Oana Manolache, marketing manager, HP Indigo labels and packaging, North America, HP Inc. “Digital presses are best positioned to meet the needs of the changing label market. The key driving forces are SKU proliferation, shorter run lengths, and shorter lead times.”

While converters recognize digital print’s potential, consumers are not as educated. “Digital printing is mostly driven by shrinking run lengths and the quality of digital output meeting or exceeding flexographic output, but most consumers are unaware of the transition,” admits Mike Barry, product marketing manager, digital solutions, Fujifilm North America Corporation, Graphic Systems Division.

“Consumers generally only experience digital adoption through the different type of high-quality label images they see being used by brands. They really have no information about print technology,” offers Mike Pruitt, SurePress product manager, Epson.

Weymans adds that the consumer actually has no preference if a carton, packaging, or labels is printed digitally. “What matters for them is that the product offers what they were looking for, and if it appeals to their requirements and desire.”

Olaf Walter, president, mprint, LLC, agrees. He expresses the sentiment that consumers don’t necessarily care about digital printing. He thinks they enjoy certain promotions like those in the beverage industry where they see their own name on a label.

It is because of this particular interest in personalization that Buckthorpe says consumers are the driving force for digital label and packaging production. “They demand more from brands like personalization, localization, and flavor variation. This change in consumer behavior is forcing brands to evaluate product offerings and marketing efforts to better connect with consumers through labels and packaging.”

Packaging companies are aware of digital print, but for many the adoption rate is slow. Juan Kim, CEO, Valloy Incorporation, says one reason for this is the fact that packaging companies are being provided with converted labels either by digital or analog systems.

Cleary and Manolache say packaging companies generally do not convert labels. If they do, they prefer digital for the same reasons as converters and consumers.

Packaging companies with digital print already in house see the benefits in action while working with converters. “Packaging companies embrace digitally printed labels as long as they give them a fast reaction, good quality, and the potential of variable data/images at a reasonable cost. Short runs and special promotions are ideal and packaging companies look to suppliers to have technologies that can support their fast-changing demands,” adds Walter.

“Today’s packaging companies are mixing both digital and conventional printed materials onto the same packaging line. Since the labels have such a broad working window, packaging companies experience no difference. The size of the reels, the frequency of changing the reels, that’s a different topic,” says Weymans.

Stewart Bell, VP sales, New Solution, argues that across all three segments there is a similar adoption trend. “Small- to medium-sized companies still outsource their printing and the larger companies where volume is possible produce their own.”

Features on Display
Converters, consumers, and packaging companies have different needs when it comes to digitally printed labels. However, universal requirements like quality and cost are similar across all three segments.

In addition to quality and cost, Walter believes converters look for a digital label printer that offers a total cost of ownership that can be broken down per label, ease of use, expandability, embellishment options, and an integrated digital hybrid system.

Kim says labels produced off of a digital label press need to be durable. Whichever ink or coating is used should protect against water, sunlight, and scratches, he offers.

Converters are looking to run standard, readily available substrates without priming or coating. “They need wide gamut color reproduction and the ability to reproduce fine text, lines, and graphics,” says Schlimme.

Label converters look to offer fast delivery times, unlimited SKUs, and changes along with top quality. Cleary and Manolache say label converters value digital for the reasons above as well as lower production costs on the majority of all label jobs.

“For the past few years, run lengths and lead times have come down, there is also pressure on price and margin. The drive to a more effective production technology—digital—provides an answer to that. No startup cost, straight from design onto press. This all allows for a more optimized, efficient manufacturing process. They can also offer new services to make just in time or personalized packaging materials,” says Weymans.

Consumers expect quality and accuracy. “They expect no defects, as well as 100 percent accurate information,” shares Pruitt.

“Traditional standards for labels and packaging remain, however, consumers are looking for a more individualized, one-to-one experience with the products they purchase. Brands increasingly use labels and packaging to create a connection to consumers’ distinct tastes and lifestyle choices,” adds Buckthorpe.

Label buyers and consumers use digital to differentiate on the store shelf. Variable data and unlimited SKUs allow regionalization, personalization, as well as seasonal labels, according to Cleary and Manolache.

Dana Goodale, director of product management, Gerber Technology, says packaging companies are similar to converters in terms of requirements. “They look for ease of integration into other printing processes, as well as complementary processes that may work outside of their mainstream production process. Reasonable cost of output, reliable equipment performance, imaging and substrate solutions that meet specific application needs, and output features that add value to finished products or save time and cost are also feature sets considered.”

Weymans says that as there is more product diversity, it becomes increasingly challenging to handle shorter runs cost effectively. “So the whole supply chain, packaging lines, etc. have been geared and focused towards the fast changeover. The decoration process being one of them. It’s not only digital printing that helps here, but also a more timely delivery and less quality issues.”

Overcoming Opposition
Any technology making inroads into a predominantly analog market is faced with some roadblocks along the way. Investment, workflow, and media runability are key challenges for digital presses designed for label output.

Colordyne identifies two challenges—estimating and understanding the total cost of digital label production, according to Buckthorpe.

“Initial investment is always a hurdle,” admits Walter. “Return on investment and total cost of ownership are metrics that these investments are evaluated by. Of course, every customer is different and has a different product portfolio,” he offers.

“The number one challenge for digital is production cost for longer runs,” say Cleary and Manolache. The number two challenge is printing niche applications—such as those that use metallic inks, highly decorated labels, and durable labels.

Workflow is another issue. “The importance of operator training with new workflows and technologies is frequently overlooked and can be the difference between successful adoption and failure. If an operator or manager doesn’t know system capabilities, then utilization will be slow,” recommends Goodale.

“One of the biggest challenges for digital adoption in regards to label printing is workflow automation, as well as the automation of maintenance functions,” suggests Pruitt.

“Through the years the label industry has grown based on the creativity people fostered, creativity in making tangible solutions with a screwdriver/hammer. Today the creativity needs to be bundled with the possibilities offered by software solutions, a field of expertise that still needs to grow,” adds Weymans.

Lastly, material compatibility is a concern. For a print house that’s been running a specific brand of media on their analog press for 50 plus years, moving to digital and figuring out the right combination of media and ink can be difficult.

“The biggest single challenge is probably the ability to move work between printing assets and achieve consistent results,” suggests Nat Davis, digital product manager, Mark Andy Inc.

While digital print’s involvement in self-adhesive materials is very accomplished, the next big challenge is moving from labels printed with self-adhesive to flexible materials, according to Jim Lambert, VP of digital sales – ink and hardware, INX International Ink Co. “The same machines that print stickers are now being configured to print on flexible films and packaging,” he shares.

Digital Label Presses
A number of inkjet- and toner-based digital label printers are available. Here, we include some of the newest models from leading vendors in the space.

Inkjet
Colordyne offers both UV and aqueous inkjet technology. The newest device is the 3600 Series UV – Retrofit. Launched in July 2017, it allows converters to add digital UV inkjet to an existing flexographic press. It prints digital CMYK plus white at speeds of up to 246 feet per minute (fpm). Available in widths of 8.5 or 12.75 inches, the 3600 Series UV – Retrofit offers a print resolution of 600×600 dpi.

A three-way partnership between Comet, INX Digital, and Uteco has produced the inkjet printing machine, Gaia, suitable for printing on flexible materials—both thin and thick films—thanks to its electron beam (EB) technology. Its alternative ink is cured using an EB compact lamp. The curing process is consistent and produces essentially zero volatile organic compounds, according to the companies.

Durst Image Technology US offers the Tau 330 Series UV inkjet, single-pass label printer. The latest development is the eight color label press, Tau 330 RSC inline with OMET’s Xflex X6 hybrid solution. The label and package printing press features a 13-inch print width combined with print speeds of up to 225 fpm at a resolution of 1,200×1,200 dpi.

EFI recently entered into an exclusive partnership with Xeikon, a division of Flint Group. Xeikon will service, support, and supply the EFI Jetrion digital inkjet label presses already in the field; as well as continue direct sales of the presses. The EFI Jetrion portfolio features opaque white ink, which extends possibilities for users. Not only do the presses print labels, but varnish, cutting, and slitting are all possible in one footprint.

Epson sells the SurePress L-4533AW, which uses water-based resin encapsulated ink. With two types of black, CMYK, orange, and green, the press’ color gamut is huge at a deltaE of 1.5. White ink also increases application options, printing on films used in flexible packaging. Epson also provides the SurePress L-6034, which uses high-speed UV ink with high-accuracy dot placement. Most of the process is automated, so the operator can run a full shift without any intervention or manual cleaning.

Fujifilm promotes the Graphium UV digital hybrid inkjet press. According to the company, the Graphium is a production class device that can be configured with flexographic, finishing, and embellishing in an inline process. It prints at a maximum media width of 17 inches at speeds of up to 164 fpm. Xaar 1001 Thruflow UV inkjet drop on demand printheads run with Fujifilm’s Uvijet Graphium UV inkjet inks—CMYK plus high-opacity white.

The Gerber EDGE FX is a digital production system that features spot color overprinting via GerberColor Spectratone. A electronic contour cutting capability cuts any shape, including kiss cutting, liner cutting, and slitting. Variable data, quick response codes, and traditional barcodes are also output using the device.

Mark Andy’s Digital Series is available as a four-color process UV inkjet printing CMYK plus white. Hybrid flexography stations are available for top coating, metallics, and cold foil. The press offers a maximum digital print width of 12.5 inches and true 240 fpm speed at-quality with a four-color process. Substrates ideal for this press include pressure-sensitive paper and film, unsupported paper, tag stocks, and light carton.

mprint offers UV ink presses, both regular and low migration UV for labels and other narrow web applications. The most recent development on the mlabel generation three includes a Digital Metal Liner module for digital foil embellishment, eight plus colors, and RFID insertion. The machine is designed as a 13-inch hybrid press, but can be outfitted with a smaller print width to start and then expanded in field.

New Solution’s NS Pro Evo digital label printer utilizes inkjet Niagara water-based dye ink with Memjet printhead technology. It is a high-speed, single-pass inkjet printer that allows a maximum printable width of 8.7 inches. To operate a complete, end-to-end solution, the NS F22 digital cutter can be added inline.

Screen recently announced the Truepress Jet L350UV+, a UV inkjet narrow web press. It targets short run, print on demand label runs up to 2,000 meters. Based on configuration it costs anywhere from $550,000 to $650,000. Of note, is the addition of a fifth ink channel—orange—to provide gamut expansion and provide the ability to match more difficult spot and brand colors. An optional Chill Roller allows for handling thick heat sensitive films.

Valloy’s TOPAZET UV 13R is a 13-inch UV LED inkjet roll-to-roll label printer. It includes six colors plus white/varnish ink and prints on any kind of uncoated media such as soft package films. The printer utilizes Ricoh GH2220 printheads. Print speed is dependent on the number of printheads, but the basic model offers about three to five meters per minute.

Xeikon offers its Panther series, a UV inkjet platform introduced this year. It includes for presses, the Xeikon PX2000—featuring an 8.3-inch web width, and the PX3000—featuring a 13-inch web width, both are available in a four- and five-color configuration. Xeikon Panther products focus on durable labels with a glossy and tactile look and feel. It is ideally suited for health and beauty, industrial chemical, beverage labels, and complementing screen and flexographic printing.

Liquid Electrophotography (LEP)
HP Indigo offers a full line of digital label presses including the HP Indigo WS6800, HP Indigo 8000, and HP Indigo 20000. These digital offset presses utilize electrophotograpy (EP) and liquid HP ElectroInk.

The HP Indigo 8000 produces output speeds of up to 262 fpm. The HP Indigo 20000 features a 30-inch width, enabling production costs to be reduced on longer run print jobs.

All HP Indigo label presses have optional inline finishing. In dual mode, inline finishing configuration operators can choose to finish inline or offline with each job to maximize productivity on each shift. The new HP GEM offers inline—with the HP Indigo WS6800—digital embellishments including digital spot varnish, tactile varnish, foil, and holographs. These digital embellishments are done inline, in register, at full speed, and are completely variable with no tooling. Embellishments on labels can be unique using HP SmartStream Mosaic software. HP Indigo digital label presses print up to seven colors, including PMS spot colors, in any order. Up to 16 color separations are printed in one pass. HP Indigo offers multiple white HP ElectroInks to meet various opacity and application needs.

Toner
Konica Minolta Business Solutions recently rebranded its bizhub PRESS C71cf to the AccurioLabel 190, a full-color label printing system. The dry toner, EP press prints at 1,200×1,200 dpi offering gradations, photographic image quality, variable printing, bar code printing, reproduction of skin tones, thin-line expression, small point characters, and solid density. It is positioned for sample to production prints in the small- to medium-volume label market.

Mark Andy’s Digital One press, targeting short-run prime labels, operates using CMYK dry toner EP. The 13-inch web width is complemented by inline flexographic decoration and converting—spot color, varnish, laminate, cold foil, die cut, strip, and slit. It prints at a maximum speed of 62 fpm at 1,200 dpi.

The MGI JETvarnish 3D Web Color + combines the MGI traditions of digital innovation in the realms of post-press embellishment and multi-substrate printing with a new approach to flexible packaging and label production. The MGI Meteor Press Series uses a specialized EP toner ink process to deliver high resolution, digital color printing on hundreds of different substrates. The JETvarnish 3D Enhancement Press Series offers dynamic enrichment of digital, offset, and flexographic printed output via unique inkjet applications of dimensional varnish and foil textures.

Valloy’s ANY-002 is an 8.5-inch LED toner-based roll-to-roll label printer that targets 200 units per year. It features white/varnish toner and RIP software designed for special effect applications. Valloy also offers the BIZPRESS 13R, which is a 13-inch LED toner-based roll-to-roll label printer.

In addition to the inkjet-based Panther products, Xeikon offers its Cheetah series, featuring a new dry toner platform introduced this year, including the Xeikon CX500—featuring a 20.3-inch web width and the Xeikon CX3—featuring a 13-inch web width. Xeikon Cheetah focuses on food safe labels, printing on a broad variety of challenging paper materials, and high quality. It is ideally suited for wine and spirits, food labels, pharma labels, and complementing flexographic and offset printing.

Exciting Times
Labels represent an expanding application in digital print. Converters, consumers, and packaging companies all look to dedicated digital label presses—both toner and inkjet configurations—to cost effectively create high-quality, short runs.

Jan 2018, DPS Magazine

By Olivia Cahoon

Electrophotographic (EP) and liquid EP (LEP) production printers utilize mature digital printing technologies that use dry and liquid toner to print onto a range of papers and substrates. Dry toners consist of pigments that embed inside polymer beads that melt to the paper surface while liquid toners use pigments in polymer beads that are dispersed in an oil that evaporates during fusing.

Compared to inkjet, EP devices are compatible with a larger variety of substrates. Smaller particles allow toner to be densely packed with color while uniform particle shapes contribute to consistency. As a result, a richer spectrum of color enables a broader variety of applications.

LEP devices utilize an alternative to liquid carriers to deliver speed and quality. HP Indigo’s LEP technology uses HP ElectroInk, which accurately places tiny dot particles on substrates for sharp, high resolution, and well-defined images.

A variety of media vendors offer substrates specifically designed for optimal output from toner-based devices.

Above: The Curious Collection with i-Tone is distributed by Mohawk and manufactured by Arjowiggins Graphic. i-Tone is a surface treatment that improves toner adhesion on substrates for HP Indigo presses.

Primary Features
While many are quick to point out the importance of quality and price for substrates compatible with EP/LEP devices, product reliability allows printers to have maximum uptime and consistency.

Craig Surette, director of business development, dry toner market, GPA, says product reliability applies to the overall benefit of specialty substrates like labels, synthetic papers, and unique papers. “Printer peace of mind, being able to run the job with confidence, and not fighting the press—these are the key media drivers we hear from our customers,” he offers.

Michelle T. Garrett, national account executive, digital and specialty papers, Verso Corporation, agrees and says print providers need substrates that deliver reliable performance throughout imaging and finishing since turnaround times are generally short.

One of the best ways to ensure a product’s reliability is to determine if the substrate manufacturer or distributor partners with the press manufacturer. “Digital substrates are designed and optimized to perform on different print engine, in partnership with the press manufacturer, so it’s important to select the right media for your print engine,” says Garrett.

Still, print quality and price are primary features that digital print providers look for in substrate selection. Mark Anderson, executive director of sales and operations, South Coast Advantage, says quality varies based upon the equipment. Substrates must be able to support transfer and toner fixation without added problems. He suggests low moisture is the difference between papers that perform and ones that don’t for many toner-based machines.

“HP Indigo requires specific surface chemistry, which allows the ink to adhere to the stock. It’s important the user tests the stock prior to placing an order to assure the proper performance is achieved,” offers Anderson.

Due to faster turnaround expectations, digital presses compete with offset. As a result, paper costs are important. While digital substrate costs should be reasonable, they are expected to be more than offset papers. With value-added applications like variable data, cost becomes less important.

EP/ LEP Specific Substrate Features
Printing on EP/LEP devices requires optimized media for each individual device. EP devices use high temperatures and pressure to fuse toner particles to the paper. This presents challenges for heat-sensitive substrates.

High temperatures mean that most synthetic materials are difficult to use with EP devices. Dan Lawellin, director, business development, Kernow Coatings, explains, “the charge profile required to form an image tends to build up a large amount of static in synthetic sheets. These synthetics tend to hold that charge, much like a balloon that you rub on the carpet and then stick to the wall using static.” Static build up can cause jams and print artifacts to appear.

To avoid static complications, Lawellin says media manufacturers incorporate features to optimize the synthetic substrate’s performance in the press. “We’ve stabilized sheets to handle the head of the fusing systems and we’ve dialed in the charge profile for synthetics, so they can take the imaging charge but quickly disperse it,” he offers.

While EP doesn’t require primers, Kirit Naik, director, research and development, America, UPM Raflatac, suggests it does need testing compatibility. For example, if high heat is used then clear, thin substrates might present printability challenges. As a replacement, a similar thickness white film can be used because it has inorganic, heat-resistant fillers. “Customers would need to evaluate hot melt adhesive-based label stocks for a dry toner system,” he explains.

Melissa Campbell, marketing manager, Masterpiece Graphix, points out that traditionally, print providers felt limited to just polyester substrates because of high temperatures required for EP. But with substrate advancements, print providers can choose more options for dry toner like synthetic paper and plastic.

In LEP systems, most of the oils are evaporated during the heat process so temperature is less of a concern. These systems present a different set of challenges including creating a film across the material’s surface when the image sets.

For synthetic papers on LEP devices, Lawellin explains that print providers bond film to film, which requires the proper surface chemistry. “We create an optimized surface that allows the LEP technology to form a strong bond with the surface, locking the color, image, and print,” he explains.

John B. Cooper, technical director, Arjowiggins Graphic, says EP/LEP substrates are separately optimized for moisture and smoothness, which is required for optimal toner transfer and toner adhesion.

Because there are fewer LEP devices than EP, some print providers may feel limited to specific materials created distinctly for LEP. However, Campbell says there are substrates engineered to perform on LEP devices as well as EP presses and many offset and flexographic machines. “These materials are tested and designed for high printing temperatures of toner presses,” she explains.

Managing Substrate Challenges
Smaller inventories and broad product portfolios present challenges for print providers when selecting substrates. Access to large warehouses for inventory and equipment is a luxury that many print providers cannot afford, therefore stocking the best compatible substrate options is critical.

“Most print providers expect suppliers to quickly turn around product requests and maintain a wide breadth of products so they don’t have to. Size notwithstanding, availability is always a critical driver,” says Scott Schweder, director of business development, Domtar.

Another challenge for EP/LEP substrates is determining which products are compatible for EP/LEP presses. Some products are cross platform and work on different types of devices while others are specifically intended for certain technologies. Joe Schember, product manager, digital specialty and paper, Mohawk, says equipment compatibility charts exist from media vendors to help printers match digital presses to available compatible media. “Because we have done extensive testing with the equipment manufacturers, these charts go beyond just stating compatibility to include specific settings by press model, hints and tips, and any other FAQs available regarding the product,” offers Schember.

Substrate specifications, specifically thickness, present limitations on some printer models. According to Jim Cirigliano, marketing manager, Magnum Magnetics, many printer models have thickness limitations and as a result, press manufacturers won’t certify media that exceeds a certain weight or thickness.

As previously noted, some presses run fairly hot—creating problems for printing substrates affected by high heat. Cirigliano says certain products are designed with these types of presses in mind. “These options include thinner overall material that falls within the printers’ limits and with constructions that perform better under heat exposure,” he offers.

Heat is particularly challenging in the plastics market. Rebecca Fuhrman, market development manager, Tekra, says high fusing temperatures with toner-based presses can limit the amount of usable film substrates because some film types can stretch or warp under high heat. This causes print registration loss or the ability to be easily processed during post-print operations. “It’s important to select a material that can handle the heat needed to fuse the toner while still meeting the application needs,” she offers.

For printing on boards, John Sarik, technical marketing manager, Metsä Board Americas, says that finding the proper board sizes can be challenging. “If you pick the wrong board, print it with a solid black, overprint it with a coating, and put it on a folder gluer only to get cracking on the 180-degree fold, then you have to repeat the process,” he explains.

Substrate Considerations
Quality, availability, and cost are primary considerations for media providers serving an EP/LEP market. By keeping customer focus in mind, Nate Gill, product manager, Mactac, says media offerings will meet and exceed customer needs.

“Moreover, the technology within the EP/LEP market is quickly advancing. Mactac takes an active role in monitoring these developments to ensure our media is available and optimized for the new equipment our customers are acquiring,” he offers.

Not all print providers produce the same applications and as a result, diverse substrate demands need to be met. Jason Depner, labels and print segment manager, TESLIN substrate products, PPG Industries, believes offering substrates with a range of application-specific grades compatible with numerous digital print processes is one of the best methods for serving each client. Different needs include certified grades for direct food contact or grades that decompose in landfill environments.

Anders Fransson, group technical and environmental coordinator, Arctic Paper, suggests the main consideration for media manufacturers and distributors is maintaining a plentiful substrate stock. He says the average delivery size is very small, roughly under 100 kg. Substrate suppliers should have several versions of substrate options with different grades, grammages, formats, and grain direction.

“To have a complete and attractive offer, the cost for keeping stock articles and handling deliveries becomes huge,” he explains. As a result, manufacturers and distributors are conscious about substrate offerings including options in different sizes and features.

In addition, media recommendations and certifications give print providers confidence that media will successfully perform. According to Brian Ayers, market development specialist, FLEXcon, certifications or recommendations for substrate options for EP/LEP presses are driven either by the market or end users. Substrate manufacturers and distributors generally test substrates with several print technologies so print providers know which options are compatible with their presses.

Manufacturers and distributors like FLEXcon also test products to ensure compliance with various agency standards. “Toner-based printers have always been used in the petrochemical market; however, due to the implementation of the Globally Harmonized System of Classification and Labeling of Chemicals, there is now a requirement for variable imaging in color where in the past it was only required in black,” explains Ayers.

Available Toner Substrates
A variety of substrates are compatible with EP/LEP production devices. Here we highlight a selection of these products.

Arctic Paper’s Munken Polar ID is an uncoated paper certified for HP Indigo printing with a high-quality print target. It includes a special surface treatment optimized for toner devices. “We also have other shade versions from cream to natural white and crisp white and high white,” says Fransson.
Arjowiggins Graphic offers Cyclus and Cocoon compatible with all major dry toner manufacturers like Canon, Konica Minolta, Ricoh, Xerox, as well as HP Indigo. Cooper says both products have excellent OEM-guaranteed toner adhesion and sheet size accuracy.

Domtar’s Cougar Digital Color Copy is photo certified for HP Indigo 5500 series and higher presses. It’s compatible with liquid or dry toner devices and is FSC certified. It features vibrant color reproduction and superior ink adhesion. Cougar is intended for brochures, business cards, direct mail, postcards, uncoated photos, and variable data.

FLEXcon DRUMcal and FLEXcon LAZRfilm products were released in 2016. A gloss topcoat is available for both substrates. Topcoat technology is used for optimum ink adhesion and liners allow consistent feed ability without curling. FLEXcon partners with HP, Konica Minolta, Lexmark, Microplex, OKI Data, Ricoh, Xeikon, and Xerox. Ayers points out that prices vary depending on adhesive and finishing requirements.

Released in February 2017, GPA offers Ultra Digital Synthetic Paper. The collection has a chemically engineered topcoat for dry toner presses and is compatible with all production-class dry toner presses including Canon, Kodak, Konica Minolta, Ricoh, and Xerox. According to Surette, Ultra Digital is guaranteed for printer compatibility, toner adhesion, and print quality. It is a soft, yet durable, synthetic print media that can be flexed and abraded. It’s available in a variety of thicknesses and sizes and doesn’t require lamination or top coats for image permanence.

Kernow Coatings offers KernowPrint for dry toner and KernowPrint for HP Indigo devices. For dry toner, the substrate is optimized with a proprietary coating designed for toner and laser printing while resisting alcohol and static. It is compatible with devices like Canon, Konica Minolta, MGI, Ricoh, and Xerox. KernowPrint for HP Indigo uses Cobalt Coating Technology to provide an optimal surface for printing and static control. “We have created a heat-stabilized material that easily handles temperatures well beyond what fusing systems produce,” says Lawellin.

Mactac STARLINER and METRO Digital substrate brands are non-ooze adhesives that withstand heat and pressure while avoiding gum buildup. Gill says the brands are available in sizes for most EP/LEP presses. STARLINER sheet products are pressure sensitive and certified for HP Indigo Digital presses. METRO pressure-sensitive sheets are suitable for kiss cuts and are used for applications like point of purchase, package identity, address, routing, and shipping labels.

Magnum Magnetics offers DigiMag PLUS and DigiMax XTRA. Both solutions are offered as polyester and paper with DigiMag XTRA as premium paper. Cirigliano says Magnum Magnetics media for toner devices are typically provided unmagnetized for easy feeding and handling. Media can be magnetized post print using a patented magnetizer solution.

Masterpiece Graphix GlassMate is an ultra-low tack, washable, removable, and repositionable decal film for indoor and outdoor use. It’s primarily used on glass or other smooth, glossy surfaces. Campbell says the proprietary adhesive system allows decals to remain in place indefinitely on most interior applications and remove easily without leaving any adhesive residue.

Metsä Board’s board products have a coating chemistry that accommodates EP/LEP devices. The board allows ink to setup on surfaces for a sharp dot reproduction. This coating technology is compatible for offset and digital inks. “The board and liners we provide are readily available by our stocking program, and we have converters, if needed, to produce the sizes needed for the industry,” says Sarik.

Mohawk offers over 1,000 digital items including Chromolux for HP Indigo and the Curious Collection with i-Tone. Chromolux is available as high-gloss papers and boards. It features cast-coated, one-side, high-gloss surfaces in a range of calipers, colors, and metallic finishes. The Curious Collection is manufactured by Arjowiggins and distributed by Mohawk. It includes seven grades with different textures. Mohawk i-tone is a surface treatment developed for the HP Indigo presses that improves toner adhesion on substrates.

PPG TESLIN TS is a synthetic paper introduced in the early 1990s. It’s used for high-quality commercial print, labels, and packaging applications that require durability. The substrate has micropores that absorb ink and toner to protect against wear from handling and abrasion. It’s compatible with a range of digital press models without requiring special coating. According to Depner, TESLIN TS is exceptionally durable and resistant to water, chemicals, and tearing. “It has a unique, soft and supple feel that helps printed pieces stand out when handled,” he offers. TESLIN TS is available in a variety of thicknesses and sizes.

South Coast is an HP recommended coater/converter. The company offers varied substrates and sizes and optimizes paper to work on HP Indigo presses. According to Anderson, optimization is recommended on substrates running on industrial one-shot presses. “Our company’s digitally optimized products can achieve high-quality adhesion and extended blanket life,” he explains.

ToneKote from Tekra uses a proprietary toner-specific topcoat that enhances toner adhesion and converts to the customer’s specific needs. It targets high-quality printing and is compatible with Ricoh, Xeikon, and Xerox devices. “We coat our film to allow for the best toner adhesion and include properties to help minimize static buildup on the sheet in process,” says Fuhrman. She believes these features ensure print quality and withstand any post processing.

UPM Raflatac recently launched a printer recommendation tool that delivers a comprehensive database of paper and film materials for a variety of digital printers. According to Naik, the tool provides product information about UPM Raflatac’s digital label stock materials and ratings for how they perform on various printers from small desktop models to large digital printers.

Verso Corporation offers several papers for toner devices including Futura. Futura’s paper construction is fiber rich for performance through the bindery. It’s designed with a patented coated surface for runability and printability that meets Canon, HP, Kodak, Xerox, and other OEM standards. According to Garrett, it’s a preferred choice for high-end projects that require output that rivals conventional offset printing.

Substrate Options
Media manufacturers address toner-based substrate challenges like compatibility, heat, and versatility with digital media lines that are optimized for EP/LEP devices. Before selecting a substrate, print providers should consider factors like stock availability, price, print quality, and reliability to ensure the best substrates for their presses and core applications are always stocked.

Jan 2018, DPS Magazine

By Olivia Cahoon

Recent advancements in digital print technology narrow the production gap between offset and digital. This includes the ability to use standard coated and uncoated stock, shorter turnaround times, and high production speeds. With continuously expanding digital capacities, print providers serve more industries.

Above: Color Ink of Sussex, WI used is Fujifilm J Press 720S, Polar 137 EMC Guillotine cutter, and Endurance Glass Cover to create 2,000 18×24-inch posters for Arizona State University.

Family Owned & Operated
Founded in 1984, Color Ink, Inc. started in a 10,000-square foot facility in Hartland, WI. The company originated as a general commercial printer that offered creative services and small format sheet-fed lithographic printing. Its original client base was about a dozen customers located in Southeastern WI.

Jim Meissner, founder, Color Ink, Inc. used his experience in commercial art and advertising to grow the company. It soon expanded and relocated to Sussex, WI.

The print provider now has over 250 customers across Canada and the U.S. and occupies two buildings with a total of 105,000 square feet of workspace. The company remains family owned and operated with a commitment to quality and innovation.

With over 75 employees, the company offers UV sheet-fed lithographic printing up to 40 inches, small format digital printing, wide format digital printing, and dye-sublimation (dye-sub). “We also have expanded our creative services to include custom displays, package design, and cross-platform media solutions,” says Todd Meissner, president, Color Ink, Inc.

Over the last ten years, the company expanded its digital printing solutions. It can print sheet sizes up to 10×10 feet on a variety of substrates including acrylic, fabric, falconboard, foamcore, paperboard, plexiglass, plastic, styrene, textiles, and vinyl.

A Digital Spread
For over 15 years digital print technology has played a role in its operation. The company’s printing equipment lineup consists of a variety of digital, wide format, and offset printing solutions. Its digital printers include the Agfa Jeti Mira MG 2732 HS; Epson SureColor S30670; S5067, and S70670; Epson SureColor F9200 dye-sub printer; Inca A4oi Onset Printer; Inca Colombia Turbo large format printer; and Xerox Versant 80 Color Performance Press.

In March 2017, the company installed the Fujifilm J Press 720S—a high-quality, sheet-fed inkjet press. It handles maximum sheets of 29.5×20.8 inches with an output of 2,700 half-size sheets per hour. Todd Meissner says the company selected the J Press for its print quality, uptime, and color consistency. “We struggled maintaining consistent color with other digital devices and our lithographic presses. With the J Press, all of those problems have gone away,” he says.

Printed sheets emerge dry from the J Press’ IR drying system. The press also uses standard coated and uncoated stock instead of specialized digital paper, two features beneficial to Color Ink.

“With the installation of the J Press, we can now offer lithographic-quality printing on a digital press. This has been a game changer for us,” says Meissner. The J Press 720S is designed for printers that need the quality and robustness of an offset press and the versatility to handle short press runs. It produces high-quality images up to 1,200×1,200 dpi with four levels of grayscale.

Approximately ten percent of the company’s work is completed on the J Press. “We are seeing gross profit margins on J Press projects to be consistently ten to 15 percent better than traditional lithographic projects,” admits Meissner.

The J Press uses a proprietary water-based eco-friendly ink that is manufactured and distributed by Fujifilm. According to the company, he water-based inks reduce cleaning and waste while producing bleed-free images.

“Our press is setup to print on coated and uncoated papers in the range of 100# text up to 24-point board. We have had success with most paper brands available in the market,” says Meissner. Color Ink typically uses Carolina Coated Cover Paperboard, Endurance Coated Papers, Anthem Plus by Verso Corporation, and Sappi coated covers.

All of the company’s prepress files are processed using Agfa Graphics Apogee workflow. Apogee allows users to control every phase of the production process from a single user interface. It integrates with different Apogee solutions like Preflight, Impose, and InkSave.

For variable projects, Color Ink uses Meadows Publishing Solutions’ DesignMerge, an add-on component for Adobe InDesign and Quark. It allows users to create customized, one-on-one marketing documents.

For cutting prototypes and packaging, Color Ink installed a Gerber Technology M1200 flatbed cutting system. The flatbed cutter handles sizes up to 85×77 inches with speeds of up to 34 inches per second. Its T3 modular head accommodates up to three tools plus a laser pointer for accurate positioning.

The company’s finishing equipment also includes an Aerocut Digital Cutter/Creaser, ATC UV Roll Coater, InPro Rhino paper cutter, Pitney Bowes DM525 Mailing System, Pitney Bowes Flow Master 12000 XL, Polar 137 EMC guillotine cutter, Pro-Tech Orca III Laminator, and Zünd Digital Cutter G3 L-3200.

Sun Devils Posters
In September 2017, Arizona State University—a repeat customer—approached Color Ink for two versions of the university’s Sun Devils athletic poster schedules.

The job was sent to the Fujifilm J Press 720S, which printed on 80# Endurance Gloss Cover.

For finishing, Color Ink used its Polar 137 EMC guillotine cutter. “The nature of the inks and cutting system allows us to handle the sheets almost immediately after printing so we are able to cut and package without any additional drying time or coating,” shares Meissner.

After receiving the print file, proofing, printing, and trimming, Color Ink shipped the posters the next day. In total, the company printed 2,000, 18×24-inch posters with a gloss enamel cover for durability and shine.

According to Meissner, if the company had printed the posters on a conventional press, it wouldn’t have been able to hit the deadline and would have exceeded the client’s budget. “The J Press allowed us to produce this project in less time and at a lesser cost than any other press we have used for this in the past,” he offers.

Print Forward
Advancements in digital print technology pave the way for print providers like Color Ink to take on more jobs with shorter turnaround times and higher efficiency.

Jan 2018, DPS Magazine