Inkjet Technologies, Imaging Files, Inks, Substrates, and Drying. Best Practices for Optimal Results. February 25 th, 2015

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1 Inkjet Technologies, Imaging Files, Inks, Substrates, and Drying Best Practices for Optimal Results February 25 th, 2015 John Palazzolo Adphos North America, Inc (513) NIR is a trademark of adphos. adphos owns more than 200 patents or patent applications on NIR technology

2 Objectives for Inkjet Printing No matter what type of inkjet (monochrome or process color) applications companies are producing (bills/statements, books, direct mail, packaging, etc.) or method they are using to do it (inkjet press, inline with offset press or offline on finishing lines) all are looking for: Faster Production Speeds Use of More Substrates (Less Expensive, Higher Gloss) Improved Image Quality / Expanded Color Gamut Lower Total Cost of Operation (TCO) Faster / Improved Post Processing (books, mailpieces) Improved (Flatter) Finished Product (books, mailpieces) 2

3 Achieving the Objectives Inkjet Technologies Imaging Files Inkjet Inks Substrates Inkjet Drying Wile we will be looking at each of these individually, all are extremely interdependent on each other in achieving the objectives. 3

4 INKJET TECHNOLOGIES

5 Inkjet Technology Implications Water Based Primary Companies Continuous DOD Piezo DOD - Thermal Kodak Panasonic, Kyocera, Konica Minolta, Xaar, Fuji Dimatix, Ricoh HP, Lexmark, Memjet Hardware Cost Ink Cost Ink Chemistry Flex. Ink Humectants (Glycol) Speed improving improving Ease of Integration 5

6 IMAGING FILES

Controlling your combined CMYK process colors will create smooth color and appearance regardless of surface type or color.

7 1st - Control Your Drops & Dots Control color, not dot gain Inkjet inks can rewet when other colors applied leaving mid and ¾ tones to gain even if the paper has been linearized. Controlling your combined CMYK process colors will create smooth color and appearance regardless of surface type or color. Eliminates rewetting of printed dots, controlling mid tone and highlight detail imagery and color small text. Traditional linearization G7 P2P Target Copyright 2015 Schilling Inkjet Consulting All rights reserved. 7

8 2nd - Control Print Quality Set the correct expectations! Always fingerprint various papers at production speeds. Understand image, line and text minimums as well as color and clarity of images. Know the impact your papers have on color and print quality. Copyright 2015 Schilling Inkjet Consulting All rights reserved. 8

9 3rd - Know Your Minimums Be aware of minimum serif and san-serif type and line weights reproducible in positive and knockout form. Paper WILL affect positive and reverse text and line weight clarity and legibility. Tip: Choose treated inkjet paper compatible with the fluid to ensure best image and text clarity. 1pt 2pt 3pt 8pt San Serif Variable Text 8pt Serif Variable Text 10pt San Serif Variable Text 10pt Serif Variable Text 12pt San Serif Variable Text 12pt Serif Variable Text 14pt San Serif Variable Text 14pt Serif Variable Text 16pt San Serif Variable Text 16pt Serif Variable Text 1pt 2pt 3pt 8pt San Serif Variable Text 8pt Serif Variable Text 10pt San Serif Variable Text 10pt Serif Variable Text 12pt San Serif Variable Text 12pt Serif Variable Text 14pt San Serif Variable Text 14pt Serif Variable Text 16pt San Serif Variable Text 16pt Serif Variable Text Copyright 2015 Schilling Inkjet Consulting All rights reserved. 9

11 INKS

12 Water Based Ink Properties Water based ink types: Dye (color achieved through organic colorant fully dissolved and suspended in liquid carrier) Pigment (typically very fine inorganic solid colorant particles suspended in a liquid carrier) Primary Ingredients: Water: 50% up to 90 % Alcohol (Glycol, Glycerin, ): 10 % up to 50 % (e.g. Piezo) with high temperature boiling (> 200 C up to 300 C) Dyes or Pigments: 10% up to 25 % 12

Developments include new polymers, pigments, and additives (co-solvents) expand capabilities and applications of

13 Water Based Ink Developments Raw materials suppliers view inkjet as a disruptive technology and are focusing and developing advanced product offerings for inkjet. Developments include new polymers, pigments, and additives (co-solvents) expand capabilities and applications of water-based inks: Drying/Curing on less porous substrates Creates new applications such as food, flexible packaging, textiles, and other markets Safer alternative to UV and LED curing inks Information provided by: 13

14 SUBSTRATES (PAPER)

15 Paper Substrate Characteristics Paper Classifications offset - uncoated (absorbent)/ coated (non-absorbent) (less $) inkjet receptive (absorbant) made for inkjet (more $) Paper Characteristics* absorption specific weight (g/m²) Coating formulation bulk/fiber structure adhesion characteristics *These characteristics highly influence each other. 15

16 Inkjet Papers Substrate Matters!! Inkjet papers are specifically designed for ink types and press platforms Papers are usually designed to match the type of print head/application system Not all inkjet inks are the same within their categories pigment and dyes Absorption levels of the papers are adjusted to the fit the application and the ink Higher levels of moisture absorption can limit the dot gain thus can leave white space or lines in the print The papers are designed to absorb, disperse and release the liquid phase of the inks Ink types 2 basic categories Pigment Based Dye based Paper is designed for each category and within a category for print head types 16

17 Inkjet Paper Types Uncoated (untreated) Designed to be used on all platforms Basis weights 24# Text to 9 Point Covers Allows ink colors to penetrate the surface to some degree Uncoated (treated) Designed to be used above 15 to 20% ink coverage Basis weights 24# Text to 9 Point Covers Uniform surface treatment allows the liquid portion of the inks to penetrate the paper while leaving most of the color on the surface Pigment based design different than dye based in many cases by manufacturer 17

18 Inkjet Paper Types Coated Papers Designed to give inkjet the equivalent finishes and uses of current coated offset printed papers. Produced in Gloss, Dull and Matte finishes. There is added complexity in manufacturing in achieving the desired gloss level while still allowing the water based inks to penetrate the surface. They also need to be able to release water in the drying process Coated Inkjet paper design is completely opposite of Coated Offset printed papers as Offset printed papers are designed to repel the water - fountain solutions. Inkjet is designed to absorb Liquids Gloss levels: Matte 20 Dull 40 Gloss 65 18

19 Inkjet Paper Types Overcoating Inkjet papers can be overcoated with Aqueous Coatings or UV Some changes may need to be made to the overcoats to compensate for the absorptivity of the papers The overcoats usually need to be thickened to allow less penetration into the paper to give a more even coverage in the printed and unprinted areas. 19

20 Utopia Inkjet Papers - What Works Where? The Utopia What Works Where brochure contains a comprehensive listing of available coated and uncoated Inkjet Papers for the different high-speed Inkjet platforms. Visit: 20

21 Ink Dot Absorption and Flow Out for Uncoated 21

22 Ink Dot Absorption and Flow Out for Offset Coated Paper TIME Dot size enlargement depending on viscosity of ink adhesion characteristics line speed Risk of print sharpness/contrast Risk of insufficient rub-resistance 22

23 DRYING TECHNOLOGIES

24 Ideal Ink Setting and Drying Process Immediate setting and drying: Sufficient power for water evaporation (and removal of moisture boundary layer - air) Moisture suction and removal Process to happen very quickly after printing Proper adhesion - no/low penetration depth into the substrate No/low paper temperature increase Minimum alcohol (esp. Glycol) content Sufficient rub resistance High energy absorption characteristics (Color independent) 24

25 Spectral Absorption Behavior for an Ink Type VIS UV midwave IR NIR 25

26 Spectral Absorption Behavior for an Ink Type In the table the average absorption for the different ink colors are listed for NIR emission spectrum as well as for a mid IR-emission spectrum. adphosnir Mid-Wave IR Absorption Ratio Cyan: 23 % 26 % 0.88 Magenta: 16 % 25 % 0.64 Yellow: 13 % 25 % 0.52 Black: 22 % 26 % 0.84 Plain paper: 12 % 26 % 0.46 Max. absorption diff: 11% 1 % 26

27 Competitive Matrix for the Different Potential Drying Systems Hot Impingement Air Conventional IR plus Air Ventilation Hot Drum plus Air Ventilation adphosnir with Integrated Impingement Air Power required - COO Space requirements Proximity to printhead PQ Color Gamut Ink Usage Paper Independence Dry Time Use Less Ink - COO Power adjustment to print width - COO: Start-up (heat-up) and start/stop capability: Dynamic response: Effect on substrate - Web Temp - COO: (finishing / final product) 27

28 INKJET AND DRYING INTEGRATIONS

29 adphosnir Dryer for Sheet Feed Applications 29

30 adphosnir Dryer for Sheet Feed Applications 30

31 adphosnir Kodak 6000 Press 31

32 adphosnir Kodak 6000 Press 32

33 adphosnir Kodak 6000 Press 33

34 HP T2XX Inkjet Press 34

35 Sketch of adphosnir in HP T2XX dryer 35

36 HP T3XX Inkjet Press 36

37 Sketch of adphosnir in HP T3XX dryer 37

38 HP T4XX Inkjet Press 38

39 Sketch of adphosnir HP T4XX dryer 39

40 Pictures of adphosnir HP T4XX dryer 40

41 Single/Duplex Installation 41

42 Single/Duplex Installation 42

43 CMYK Application 43

44 CMYK Application 44

45 Lottery Ticket Application 45

46 Lottery Ticket Application 46

47 CONCLUSION:

48 Objectives for Inkjet Printing Faster Production Speeds Use of More Substrates (Less Expensive, Higher Gloss) Improved Image Quality / Expanded Color Gamut Lower Total Cost of Operation (TCO) Faster / Improved Post Processing (books, mailpieces) Improved (Flatter) Finished Product (books, mailpieces) 48

49 Achieving the Objectives Due to the interdependencies, a coordinated approach including all variables is recommended. 1. Inkjet Technologies Choose the technology that best fits your needs. All have different strengths and weaknesses. If you already have chosen your tech., go 2. Imaging Files Optimize your files for the inkjet tech., inks, and papers you are or want to use. Get outside help if needed 3. Inkjet Inks Depending on the inkjet technology, you may be able to get different inks to help you meet your objectives. But may not 4. Inkjet Drying Has the most impact on over all COO 5. Substrates - #1 Cost Factor 49

50 THANK YOU!!! Visit adphos at Xploration 15 Booth

Key success factors for developing and commercializing a successful aqueous inkjet product: A specialist point of view vs. a generalist perspective

Key success factors for developing and commercializing a successful aqueous inkjet product: A specialist point of view vs. a generalist perspective Oct 24 th 2018 Hamid M. Shirazi Ph.D. Product Manager,