Technology & Innovation Series - printing.org · TECHNOLOGY & INNOVATION SERIES • APRIL 27–30...

Welcome to the

Technology & Innovation Series

TECHNOLOGY & INNOVATION SERIES • APRIL 27–30

Agenda1. Helping to Build a More Sustainable Food System

Todd Fayne, PepsiCo; Monday, April 27, 2:00–3:00 p.m. EDT

2. An Ink Supplier Perspective on Industry 4.0Juanita Parris, Sun Chemical Corp.; Tuesday, April 28, 2:00–3:00 p.m. EDT

3. Technology Innovation and the Success of FailureDavid Crawley, University of Houston; Wednesday, April 29, 2:00–3:00 p.m. EDT

4. Industrial Custom Printing: A Status ReportCraig Reid, CTR Resources, LLC; Thursday, April 30, 2:00–3:00 p.m. EDT

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Logistics and other items Adjust the volume on your speakers, use a headset for best sound quality Questions can be submitted at any time in the questions panel Recording of this session will be provided


Technical Association of the Graphic Arts (TAGA)

Professional association dedicated to research and innovation in graphic communications and related technology

More than 4,000 papers published, written by scientists and researchers

Annual conference held every March Directed by 23-person TAGA Board;

part of Printing Industries of America www.taga.org


Event Sponsors


Industrial Custom Printing: A Status Report

Craig ReidCTR Resources, LLC

Agenda

Industrial DTO/DTS Inkjet► Direct To Object / Direct To Shape Definitions &

Segments► Industrial Inkjet Components► System Design Examples► “Off The Shelf” or Custom Integration?

© 2020 CTR Resources, LLC

Definitions – DTO/DTS SimplifiedDirect-To-Object Inkjet► Jetting directly to an object in a

single plane (single side).► Typically imaging to a flat surface

or limited area of a shaped object.

Direct-To-Shape Inkjet► Jetting directly to a shape in a

three dimensional way.► Typically imaging to a shape that

is rotating, moving in a way to image all sides, or the printhead is moving around a shape to image.


Market SegmentsSampling of segments and applications for DTO & DTS


Market Segments► Promotional / Personalization

– Giveaways– Drinkware– Electronics– Pens– Tools– Lighters– Gifts / Favors– Sporting Goods– Etc.


Market Segments► Industrial Product Decoration

– Drinkware– Plateware– Construction– Parts– Electronics– Sporting Goods– Coding & Marking– Etc.


Market Segments► Packaging Graphics

– Bottles– Tubes– Containers– Glass– Metal– Plastics– Flexible Film– Smart Packaging


Inkjet Technology System Components► Printheads► Chemistry► Drive Electronics / Ink Delivery System► Substrate Pretreatment► Curing / Drying► Substrate Handling (Transport)► Software (Print Production Workflow)► Finishing


Inkjet Chemistry

Types► Energy Cure (UV, LED UV, EB)► Aqueous (Dye, Pigment, Emulsion)► Conductive► Solvent ► Hybrid► Primers► Coatings► Colors

Factors To Consider► Substrate compatibility?

– 1 substrate type, multiple, consistency, pre-treatment, primer, etc.

► Performance requirements?– Adhesion, abrasion resistance, light fastness,

chemical resistance, color, etc.► Safety requirements?

– Migration, dermal, other standards or qualifications, etc.

► Post Print handling requirements?– Finishing, embellishments, etc.


Inkjet Printheads

Types & Specs► Thermal► Piezo► Native Resolution► Drop Size► Nozzle Configuration► Chemistry Compatibility► Recirculation Capability► Duty Cycle

Factors To Consider► Type of substrate(s) will have influence on

chemistry options, which will in turn influence printhead type and model.

► Shape of substrate and distance for jetting will influence printhead selection.

► Will the system be a single pass or multi-pass configuration?

► The intended application will dictate the quality requirements for color and image fidelity.

► Certain chemistry and colors require recirculation.


Inkjet Drive Electronics & Ink Delivery System

Factors To Consider► The ink delivery system must be compatible

with all performance factors, including:– Chemistry selected for application.– Temperature control at full print speeds.– Full filtration flow rate.

► Are there requirements for de-gassing or oxygen control?

► Printhead vacuum/pressure control.► Data processing flow at full print speeds.


Inkjet Pre-Treatment / Curing / Drying

Factors To Consider► The performance requirements for a particular

application may suggest the need for pre-treatment prior to jetting the colors? i.e. Corona, Plasma, Flame, Primer?

► If pre-treatment is indicated, will it be in-line of off-line.► Depending on the substrate and application heat from

curing or drying can be a significant factor, and may dictate system design.

► Will there be any ‘wet on wet” in the process?► Will there be a coating added after printing?

Conventionally applied or jetted?


Print Production Software

Function► Job Database► Production Workflow► RIP / Color Management► Interface to Print Driver

Factors To Consider► Profiling required for each substrate to

ensure color predictability.► If printing variable data, will the software

keep up with the print speed?► If converting from analog printing,

changes in job preparation and potentially color model workflow (Spot,CMYK,RGB) may be required.

► Spot color qualification with print buyer advised.


Inkjet Substrate Handling

Types► Flatbed

– Moving Gantry– Moving Bed

► Vacuum Belt► Conveyor Belt► Rotary Cam / Turret / Mandrel► Robotic Arm► Custom

Factors To Consider► Production volume and speed

requirements.► Application specific or need to be

flexible to produce many applications?► Capital equipment budget and ROI?► Commercial availability or custom

design?► Labor vs. Automation in the loading and

unloading?► Reliability expectations?


Inkjet Substrate Handling

Flatbeds (Scanning head multi-pass)► Can be lowest entry level capital cost.► Moving gantry style can be productive for large

DTO templates, but limited for some DTS.► Moving bed style may have limited size, but using

rotary tool can enable DTS for at least very small production.

► Either type of flatbed provides flexibility to produce other print applications such as industrial, graphics and signage.

► Speeds and quality vary greatly, along with cost.

Small Moving Beds

Moving Gantry

Object Template

Large Moving Bed

Rotary Tool


DTO Inkjet Substrate HandlingVacuum Belt (a.k.a. Hybrid Flatbed – multi-pass)► Can typically produce DTO templates,

sometimes with some automation.► Rotary tool is sometimes possible, but typically

more difficult than a moving bed. ► Offers flexibility to produce other rigid print

applications as well as flexible roll-to-roll applications. Such as: Graphics, Signage, and Industrial applications.

► Speeds and quality vary greatly, along with cost.

Entry Vacuum Belt

Open Style Vacuum Belt

High Speed Vacuum Belt


Inkjet Substrate HandlingConveyor Belt (multi-pass and single-pass)► Sub $100k systems available if speed

requirements and production volume is low.► Single-pass narrow belt systems can produce

high quality and very high production speeds. Range from $150k-$400k.

► Some single-pass belt systems use optical registration to locate the object others use “shuttle templates”.

► Typically limited to DTO on a flat or nearly flat imaging surface.

Multi‐pass Conveyor Belt

Single‐Pass Conveyor Belt

Single‐Pass Conveyor Belt w/Shuttle


DTO Inkjet Substrate HandlingIndustrial Application Specific Designs► Single-pass or multi-pass► Conveyor, vacuum belt, or gantry ► Custom, application specific chemistry► Manual or robotic loading/unloading

Wood & Aluminum

Ceramic Tile

Flat Sheet Glass


Example – Specific Purpose X-Y-Z Vertical Inkjethttps://www.ricoh‐digitalpainting.com/en/products/var/

Ricoh Digital Painting Company, Ltd.

Vehicle Art Robo:• Inkjet direct to vehicle surface as

alternative to PVC wraps• Custom printheads to fire pigmented

solvent “paint” at up to 100mm distance• Curved and uneven surface tracing• Printable size to 13m wide x 3.25m height


Direct To Shape (DTS) Inkjet Design Types► Desktop or flatbeds using rotary tool► Purpose built entry level cylindrical ► Conveyor and Shuttle for shapes► Single Unit Station cylindrical mandrel► Station to station horizontal turret or clockface carrousel ► 2 Point linear or turret horizontal – cylindrical and other shapes► 2 Point carrousel vertical – cylindrical and elliptical shapes► Track mandrel vertical► Track shuttle horizontal► Turret ink / foil transfer► Robotic 3D/4D


Entry Level DTS/DTO Small Flatbed Examples

Mutoh ValueJet 426UF LogoJETMimaki 3042/6042 Roland VersaUV

DCS 1800Z

Templates & Rotary Tools


Rotary Tool Example Video

Single Rotary Tool

https://www.youtube.com/watch?v=CD4T3wzimJQ

Ganged Rotary Tool


Entry Level Purpose Built Industrial Models

BottleJet 2

https://www.youtube.com/watch?v=qwB4RNBCkQo


Inkjet Substrate Handling – Flat Sided ContainersConveyor Belt (single-pass)► Suitable for rectangular or square containers, printing one

side at a time. Custom configured systems.► Single-pass simple narrow belt systems can produce high

quality and very high production speeds. Range from $400k-$800k. More sophisticated robotics (such as flip and re-feed) can be $1MM+

► Some single-pass belt systems use optical registration to locate the object others use “shuttle templates”.

► Typically limited to DTS on a flat or nearly flat surface.

Single‐Pass Conveyor Belt

Single‐Pass Conveyor Belt w/Shuttle


Example – High Speed Single Pass Conveyor, Plastic Caps https://www.youtube.com/watch?v=U_W9ktk9z2o


Example Shuttle Style Conveyor W/Roboticshttps://www.youtube.com/watch?v=RpuX9HRoReQ

• PP (transparent)• 4.800 parts per hour• Double white + CMYK• Plasmapre‐treatment• LED for pinning and UV for end curing• Vision inspection on print quality• Robotic loading and unloading included


Inkjet Substrate Handling – Cylindrical

Rotary Cam / Cylindrical Mandrel / Single Unit Station► Single unit cylindrical mandrel systems are

typically manual load and unload but offer good versatility – primarily aimed at promotional products applications.

► Only seconds to print each piece, but manual load and unload significantly reduces productivity and increases operating costs.

► Range from $125k-$225k. Relatively high ink costs.

► Potential for use as prototyping in consumer packaging creative department.

Single Unit Cylindrical Mandrels


Example Dedicated Cylindrical – Helix®

• Print up to 8.5” tall• 360° printing


Inkjet Substrate Handling –CylindricalCylindrical Mandrel / Station to Station Clockface Design► Multi-unit mandrels in a clockface design with individual

stations for loading, jetting, curing, un-loading, etc.► Speeds vary greatly by size (circumference and length)

of shape. Models from 33 – 100 per minute. ► Robotic or push on single point vacuum, some are

beginning to include 2-Point object holding on the mandrel to accommodate more shape options.

► Inkcups Revolution unit introduced at PU2019, starting at $450k with manual load onto conveyor. Others - $600k+

► Space efficient, imaging accuracy questioned in early models.

Station to Station Clockface Design


Example – Cylindrical Mandrel Clockface Design

• Dubuit MD9360


Inkjet Substrate Handling –Flexible or Rigid CylindricalCylindrical Mandrel / Station to Station Horizontal Turret Design► Typically 1 to 2 mandrels per station. Individual

stations for load/un-load, pre-treatment, priming, colors, and varnish.

► Speeds vary greatly by size (circumference and length) of shape. Models from 70 – 240 per minute.

► Most are single point vacuum or sleeve mounting, with systems primarily designed for either tubes or cups.

► Range from $800k-$2+Million.

Station to Station Cylindrical Turret(a.k.a. “Wagon Wheel”)

Example – Turret Carrousel Style High Speed Cups

• Up to 250 Cups / Min.• Fully Robotic• Straight sided or

tapered cups• New Bottle version

up to 80ppm @90mm

• Digitube version up to 165ppm

© CTR Resources, LLC© 2020 CTR Resources, LLC

Example – High Speed Tube Inkjet Horizontal Mandrel Turret

K15 Series

High Volume, Longer Runs

• Rotary Index table• Scalable ‐ 6 to 24 stations• Round, oval, flat, odd shapes• Glass, plastic, ceramic, stainless

substrates


Inkjet Substrate Handling – CylindricalTrack Mandrel Design - Vertical► Single point mount on mandrels that ride around

station to station on a track.► Primarily designed for beverage cups but could be

modified for other wide mouth containers with a size limitation. Up to from 13 per minute. (Assuming no indexing required as it does not do spiral imaging.)

► Manual load version introduced in 2017 with relatively low sales success, manufacturer claims new robotic model coming for 2020

► $400k for manual version.

Track Mandrel Design ‐ VerticalStation to Station


Example – EPS XD-360 Rotary With Conveyor “Track”

• Up to 13 PPM• Manual or robotic

• Straight sided or tapered cups and bottles

https://www.youtube.com/watch?v=hzhjF5xxZr8

© CTR Resources, LLC© CTR Resources, LLC© 2020 CTR Resources, LLC

Inkjet Substrate Handling – Cylindrical

Cylindrical Turret Track Shuttle Design - Horizontal► Multiple objects pushed onto a shuttle with

multiple mandrels and moved around the track to be jetted then un-loaded. Friction or vacuum single point connection.

► Primarily designed for tubes and aerosol cans. 150 – 250 PPM. Up to 14 colors.

► Image quality samples look good, although very few installs per each manufacturer.

► $1.2M - $1.6M.

Track Shuttle Design ‐ Horizontal

Velox IDS250© CTR Resources, LLC


Inkjet Substrate Handling –Cylindrical & EllipticalStation to Station 2-Point Turret Design - Horizontal► Typically for rigid to semi-rigid objects that need 2

points of holding to be rotated underneath the printheads. (a.k.a. “Base Plate / Nose Cone” Design)

► Speeds vary by size and shape. Models from 15 –100 per minute. Objects robotically loaded and unloaded.

► Elliptical and other shapes use a “cam following” design to maintain the printhead height to substrate distance

► Range from $800k-$2+Million.

Station to Station 2‐Point Horizontal Turret(a.k.a. “Base Plate/Nose Cone”)


Example – High Speed Cylindrical Cartridges - Turret

https://www.youtube.com/watch?v=WbCKDIk6WOQ

• 1200 dpi• 80 ‐ 240 PPM• Full Automation


Example – High Speed Beverage Glass Inkjet


Example – Linear Multiple Rigid Shapes


Flex Jet Art 1800 Linear• Cylindrical, Rectangle, Square, Oval, on same system

• 210mm H, 130mm W• 1‐5 PPM• Semi or Full Auto• ~$600k

Example – 2-Point Turret Multiple Shapes


Flex Jet Art F08/F12 Rotary• Cylindrical, Rectangle, Square, Oval, on same system

• 210mm H, 130mm W• 10‐50 PPM• Full Auto• ~$1MM‐$1.6MM

Inkjet Substrate Handling –Cylindrical & Elliptical

Station to Station 2-Point Carrousel Design - Vertical► Typically for rigid to semi-rigid objects that need 2

points of holding to vertically passed by the printhead for jetting

► Speeds vary by size and shape. Models from 13 –600 per minute.

► Object robotically loaded onto base plate then nose cone secured to enable independent rotation of the object along with independent carrousel movement. (enabling multiple shapes).

► Range from $1.2M - $2+M.

Station to Station 2‐Point Vertical Carrousel(Independent object and carrousel movement)


Example – Vertical Carousel Irregular Shapes

https://www.krones.com/en/products/machines/decotype‐select‐direct‐printing‐system.php

• DecoType Select, 166 ‐ 400 PPM

• DecoTypeCompact, 83 PPM

• Full Automation


Inkjet Substrate Handling – CylindricalCylindrical Turret Ink/Foil Film Transfer Design -Horizontal► Ink or Foil Imaged to transfer film, then

transferred to cylindrical shape.► Introduced at the K Show – October

2019► Speeds, pricing, and specs, TBD.► Foil option may be possible to use

underneath direct inkjet as well.

Turret Ink Film Transfer ‐ Horizontal

Turret Foil Transfer ‐ Horizontal


Example – IDD (Indirect Digital Decoration)

• Inkjet Ink Film Transfer


Example – DIF (Digital Inline Foil)

• Digital Inline Foil


Examples – Robotic DTS Industrial 3D/4D

Robotic Inkjet – Shapes and Objects

Robotic Inkjet – Aircraft

Robotic Inkjet – Wall Printing

Robotic Inkjet – Bucket Printing



Q&A


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Technology & Innovation Series - printing.org · TECHNOLOGY & INNOVATION SERIES • APRIL 27–30...

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