From glossy samples to informed decisions

Something that looks good at a trade fair may not necessarily be practical in everyday use. Print samples presented under ideal conditions cannot always be replicated in real production environments. Those who base their decision solely on their initial visual impression may overestimate actual performance. This article shows you how to evaluate samples systematically and measurably, helping you to make an informed investment decision.

In recent years, inkjet systems have reached an impressive level of maturity. However, this also makes it more difficult to realistically and objectively assess the performance of specific systems. While manufacturers want to demonstrate performance with impressive print samples, not every sample is suitable for an objective comparison. Therefore, request specific comparison prints on different materials and do not rely solely on visual appearance. Instead, apply clear measurement criteria. Only by combining subjective impressions with objective analysis can a reliable basis for decision-making be established.

It's nice when it looks good. But, of course, that's not the whole picture. The actual quality only becomes apparent when you take the figures into account as well. When evaluating samples, therefore, pay particular attention to the following technical indicators:

• Optical density and colour accuracy: What looks rich and brilliant at first glance may not be as impressive under the magnifying glass. Only precise measurements reveal how colour-stable and reliable a printing system really is. It is particularly important to check whether the density values remain consistent when printing on different materials. This clearly indicates whether the machine delivers stable results in everyday production, rather than just in the showroom.

• Colour space (gamut): Not all systems reproduce colours equally well on paper. The decisive factor is how large the colour space is and how reliably it can be used. Those who regularly work with corporate colours or have to meet Pantone specifications will benefit from a broad, easily controllable colour space. The closer the system gets to the desired colour value, the less readjustment will be required later with profiles and corrections.

• Resolution and detail sharpness: Fine lines, tiny fonts and clear contours are a real challenge for any printing press. This reveals how accurately and cleanly the system handles details. Above all, uniform sharpness at edges, whether in light or dark areas of the image, reveals whether tone value transitions are reproduced consistently and without fluctuation.

As with any long-term investment, it is important to consider more than just the initial cost. Operating costs and process details are also crucial factors to consider when making an assessment. When talking to manufacturers, you should therefore ask the following questions: 

• Speed versus quality: How quickly was the sample printed, and how does high resolution affect this? The decisive factor is whether the machine can produce clean results at reduced speeds. The system is only suitable for everyday use if quality and stability are maintained at realistic production speeds.

• Ink consumption and colour profiling: Colour profiles are more than just a setting; they significantly impact ink consumption. A well-calibrated, neutrally balanced profile demonstrates the system's true efficiency. If the sample appears unnecessarily 'bold', this may indicate excessive ink application, which directly affects the budget. 

• Primer use: Has the substrate been pre-treated? If so, it is worth taking a closer look. Targeted, selective primer application can reduce costs without compromising quality. It is interesting to compare samples with and without primer, as this indicates how adaptable the system is to changing materials.

• Total Area Coverage (TAC): Total area coverage is a critical factor, especially with strong colour areas or difficult substrates. If TAC is too high, it can lead to drying problems, instability, or poor adhesion, particularly at high printing speeds. An effective system strikes a balance between colour effect and production reliability.

A modern printing workflow extends beyond the print head. Therefore, you should also consider the long-term costs and expenses associated with the following: 

• Maintenance and wear: How robust are the print heads during everyday use, and how frequently do they require cleaning or replacement? Although many processes are now automated, it is worth taking a close look at maintenance intervals, cleaning cycles, and unplanned downtime. After all, reliable planning requires a system that performs well not only under ideal conditions, but also experiences minimal downtime during normal use. 

• System integration: Does the new machine integrate seamlessly into your existing processes, or does it require complex workarounds? Ideally, modern systems can be connected directly to your MIS or ERP environment. Interfaces such as JDF or JMF ensure that job data is transferred automatically. This streamlines the workflow and reduces sources of error, which is particularly advantageous when personnel resources are limited.

• Quality assurance: The sooner an error is identified, the easier it is to correct, and modern AI-supported inspection systems excel at this. They detect deviations in real time and intervene automatically before rejects occur. An effective system does more than just report errors; it also actively ensures that processes remain stable and that quality is reproducible.

The ink transfers the motifs onto the substrate. This affects the outcome in terms of both economy and quality.

• Ink chemistry: Water-based inks are considered more environmentally friendly and are particularly suitable for graphic applications on paper or cardboard. UV inks, on the other hand, are ideal for specific requirements, such as printing on non-absorbent materials or enabling immediate further processing. In both cases, the advantages only become apparent if the ink is compatible with the existing workflow.

• Material diversity: Request samples of the materials you actually use. The more substrates that are compatible, the more flexible and future-proof your offering will be.

Upgrading to a new printing solution involves more than just that. It's a strategic decision. This was clearly demonstrated by the developments showcased at the last drupa exhibition. Inkjet technology is now ready for practical use. However, the choice of system should be based on clear, verifiable criteria.

Colour fidelity, density and edge sharpness, coupled with transparent performance values such as print speed, ink consumption and primer requirements, enable systems to be compared. This transforms uncertainty into a competitive advantage. Prioritising measurability is a wise and forward-thinking investment strategy.