Inkjet – the great hope!

Our lives are changing – and with them the printed products we buy, order and produce. Inkjet printing is unique not only in terms of the diversity of its applications. Rather, this also applies to the range of printing systems on offer. It ranges from affordable entry-level solutions to high-end production lines for ‘lights-out manufacturing’ processes – that is, fully automated production processes in dark factories where no manual operator intervention is required. The breadth of this range can reduce the risk associated with venturing into new printing applications. It also enables the printing industry to explore new possibilities.

There are now more than eight billion people living on our planet. We can travel around the globe and exchange data and information. Our habits and the way we communicate have changed. It is therefore not surprising that the world of printing is also changing. Whilst some traditional printing techniques are slowly dying out, others remain remarkably stable. At the same time, new areas of application are opening up for printing.

Print service providers are responding to this change by expanding their offerings to include additional print applications. At the same time, branded goods manufacturers are seeking new ways to market their products, publishing houses are looking for ways to disseminate their information, and private individuals are seeking ways to enhance their lives. Demand is being driven by all customer groups, particularly when it comes to small print runs and short turnaround times. An online presence makes it easy these days to showcase and promote new products, with recommendation algorithms – and in future, AI – aimed at upselling or showcasing additional products.

Nevertheless, one challenge remains: the printed materials for these new applications must first be produced. In some cases, a partnership with other print service providers is the best option. In other cases, it makes more sense to retain the capacity and more of the value-adding production processes in-house – thereby enabling a quick and flexible response. In particular, machines that can handle a wide range of applications or require lower capital investment can help to seize new opportunities.

As an analyst of printing processes, I am still amazed by the many possibilities offered by inkjet printing. It has contributed to the democratisation of the printing press market. This is because the manufacturers of these machines have access to a wide range of inkjet printheads, inks, drying systems and solutions for the feeding and transport of substrates from many different suppliers. From this range, they can select and combine their system components as required. There are more than 20 manufacturers of inkjet printheads and an even greater number of ink manufacturers active in the industry. Many companies offer solutions for the feeding and transport of substrates. It is even possible to modernise old printing or finishing machines. Furthermore, inkjet printing offers decisive technological advantages: it is a truly contactless process and can – at least in theory – print on a wide variety of materials and formats.

The solutions offered for the various market segments are correspondingly diverse. Label printing has experienced a veritable boom in recent years. There are currently more than 40 models of inkjet label printing presses available on the market. Printing on corrugated board has also gained momentum – with around a dozen single-pass printing presses currently available. By contrast, development is progressing more slowly when it comes to solutions for printing folding cartons and flexible packaging. However, several inkjet printing press models have recently become available for these market segments as well, or are due to be launched shortly. Printing on metal – on drinks cans and sheet metal – is also seeing growth. Across all segments, fully-fledged inkjet production printing systems are gradually matching the productivity of conventional printing presses, albeit at prices comparable to those of high-end printing presses.

On the other hand, there are more affordable alternatives that enable printing on labels, cans or pouches starting from low five-figure investment sums. Large-format printing systems with scanning heads can be a cost-effective alternative for flat packaging materials. These too are available from similarly low investment levels. However, they offer lower productivity, and there are often limitations regarding materials and quality. Nevertheless, it is advisable to explore what opportunities they might open up in the market. An alternative to this could be inkjet printing presses that cover additional applications. Examples include the B2 inkjet presses from Fujifilm, Konica Minolta and Komori, and the B1 presses from Landa. These solutions print on a wide range of different materials and grammages. Customers of these companies use them in a variety of applications.

The strength of inkjet printing is sometimes evident in the post-press finishing stages following packaging or commercial printing. For example, unique effects such as raised, tactile textures can be achieved by applying clear inkjet inks. Duplo, MGI, Scodix and Steinemann offer solutions for the finishing of printed sheets. Koenig & Bauer Kammann has extended this process to the printing of textures onto spherical containers.

In addition to commercial and packaging printing, there are many other markets where printing takes place. Many of these have remained under the radar of the commercial printing industry. For example, inkjet printing is used in decorative printing on flooring, panels, ceramics, glass and many other surfaces. There are even wallpaper manufacturers that print rolls of wallpaper with bespoke designs. During the pandemic, home décor experienced a boom, and thanks to new technical possibilities, more and more surfaces can be printed with decorative patterns. Inkjet technology is also experiencing rapid growth in the printing of textiles and clothing. From soft signage (textile advertising) and textiles for interior use to fabrics for fashion items or the printing of entire garments – there are countless possibilities here, with solutions for all areas of application. In this market segment, affordable entry-level models also allow for a low-risk start in printing small batches, whilst high-end production lines meet the demands of industrial-scale production.

Not all substrates are flat. However, there are also inkjet solutions for printing on three-dimensional objects. Roland DG and Mutoh have recently unveiled new printers for printing on smaller objects and merchandise. The Monster Jet from Azonprinter can even print on objects up to one metre in height. For even larger objects, possibilities for direct printing using robotic arms have already been presented. There are several projects in this area. However, they are still at an early stage of development.

Furthermore, the possibilities of inkjet printing are not limited to surfaces. Rather, 3D printing opens the door to additive manufacturing. In 3D printing, inkjet technology can capitalise on innovations developed for other markets. It benefits from the widespread availability of printheads, inks and control electronics. Whilst products manufactured using 3D printing differ significantly from printed paper, However, their expertise in data processing, colour management, customer relations and logistics can provide a competitive advantage for print service providers in this area.

If print service providers cannot find the right solution for specific printing requirements on the market, so-called inkjet integrators can help them find bespoke solutions. Companies such as Bergstein, Cadis, Colordyne and Neos offer the consultancy and engineering services that customers need to put together bespoke printing solutions. Alternatively, customers can ‘build’ their own solutions by investing in printing solutions and control electronics from suppliers such as Domino, Fujifilm, HP or Kodak, amongst others. Memjet recently unveiled its Durabolt printing solution, which the company describes as a ‘print engine in a box’. Building your own integrated printing systems naturally requires more than simply purchasing such printing solutions. Yet, in fact, thousands of such systems are already in use today.

The appeal of inkjet printing lies in its simplicity. In many cases, it requires components with very few moving parts. In some instances, setting up and operating the machines is as simple as the press of a button. This makes them easier to work with, which, in times of labour shortages, is an advantage that should not be underestimated. High-performance printing machines can be complex and demanding to operate. However, with inkjet printing, there is always the option to start small and test out different markets with manageable risk and low investment – and to expand as demand grows.  

Technology is not an end in itself. Every investment must be underpinned by a business plan or, at the very least, a business idea. However, it is strongly advisable to set out and explore where the market offers future opportunities. Printing is done on far more materials than just paper. Creativity has always been the driving force behind the printing industry – so you should draw inspiration from the printing applications showcased at trade fairs, open days, seminars or user meetings.

Admittedly, with such a wealth of options, it is difficult to keep track of everything. drupa 2024 offers a fantastic opportunity to discover a wide range of applications in one place and to obtain first-hand information from both well-known and lesser-known manufacturers. It’s time to step out of your comfort zone and explore the halls you haven’t visited yet. The same applies to the special forums ‘touchpoint’ and ‘drupa next age’, which are taking place alongside the trade fair.