People & Print ICMA EuroForum October 2015
General trends and impact valid for all print applications Urbanisation Globalization Mobility New Work New Learning more and faster orders with smaller quantities but w/o compromising offset quality standards high pressure on process cost increased ecological requirements increased security demands Individualization Health e.g.: Laminates 3D objects Folding boxes packaging & labels.. and cards! Connectivity Neo Ecology Silver Society ICMA EuroForum, October 2015 Seite:2
KBA Group & Digital Competence Center Main business fields Production Sheetfed printing Web printing Bank note / Security Metal / plastics Marking and coding Flexible packaging Glass Production casting, large parts prismatic, rotating parts, gears, cams, rollers, surface coating, preassembly For KBA and external customers Small to largeformat presses for ommercial, packaging, books,posters, displays Substrates from lightweight stock to corrugated board and plastics Hybrid systems offset/digital Digital sheetfed for packaging Workflow(s) Consumables Offset and Inkjet web presses for newspapers, inserts, magazines, catalogues, flyers, books Paper logistics Services for own and thirdparty presses (PHS) Contract construction for external customers Special printing presses for bank notes Special security technology Systems for pre-press, quality control and postpress Bank note design service KBA- MetalPrint Solutions provider for printing, coating, and drying of metal sheets Metal packaging for food, cosmetics and tobacco products KBA-MePrint Waterless offset for can and tube printing KBA-Metronic Analogue and digital Inkjet, laser, hot stamping and thermal transfer solutions for marking and coding Implementation in production lines for industrial products and packaging made of various materials KBA- Flexotecnica Flexo and converting presses for nonabsorbent materials, such as film KBA-MePrint Waterless offset for labels and film printing KBA- Kammann Screen und digital presses for decorating premium hollow containers made from glass, plastic and metal Cosmetics, perfume and spirituous beverage products in the top price class Consultancy & Inkjet Development Support Activity coordination for the KBA group Digital Competence Center ICMA EuroForum, October 2015 Seite:3
The essential technology question more and faster orders with smaller quantities but w/o compromising offset quality standards increased security demands high pressure on process costs increased ecological requirements good points, but wasterbased inkjet? ICMA EuroForum, October 2015 Seite:4
Why waterbased inkjet ink didn t materialized for plastics A valid question is: As water based single pass inkjet with piezo inkjet heads is that much advantageous, why wasn t it available so far? UV and solvent (inkjet) is an simple ink technology known for a long time. That s the reason it was used for fast market introduction despite obvious restrictions. Nowadays we understand the ink physics much better, time for the next stage of water based high speed / single pass inkjet inks ICMA EuroForum, October 2015 Seite:5
Why water based inkjet ink now will become reality the By using Van-der-Waals-Force this: http://www.google.de/imgres?imgurl=http%3a%2f%2ffootage.framepool.com%2fshotimg%2fqf%2f386198891-saugnapf-gecko-bionikpfote.jpg&imgrefurl=http%3a%2f%2ffootage.framepool.com%2fde%2fbin%2f1870165%2cbionik%2cgecko%2cfu%25c3%259f%2f&h=540&w=960&tbnid=enqlibqhfarz_m%3a&docid=s1g1ka6nsccz0m&ei=bnx6vyk3iek7ygo63zugda&tbm=isch&iact=rc&uact=3&dur=663&page=1 &start=0&ndsp=37&ved=0cdwqrqmwcwovchmigp3e2kr-xwiv4p1ych267gbe Water based ink can stick reliable on closed surface substrates like plastics using molecular polarity. But what happens if certain substrates vary on polarity? Using substrate specific ink can t be a solution A solution can be to add a primer layer which polarity fits both, various substrates and constant ink, acting as neutral glue. Works, but with obvious disadvantages as adding costs, layer thickness, look & feel changes etc. Not good at all. A perfect solution will be to incorporate the primer part in the ink! The right polymers can do this by encasing any pigment! No rocket science just hard scientific work. enough about ink let`s talk about business. ICMA EuroForum, October 2015 Seite:6
more and faster orders with smaller quantities but w/o compromising offset quality standards Digital printing solutions can be integrated in E.R.P. systems and fully automized Requirement No over stocking on-demand production Productivity up to 3x times higher than offset, 300.000 up to 1.500.000 cards /h (sheetfed) and 30.000 150.000 cards/h (single card printing) Both sheet and single card production possible, no change / compromise Variable Date processing part of the print process vs. additional production step if offset printed No extra drying time: Ready to finish immediately after print / inline-finishing possible Interruption free sample printing (w/o production stop) ICMA EuroForum, October 2015 Seite:7
more and faster orders with smaller quantities but w/o compromising offset quality standards Single pass waterbased piezo inkjet printing can meet offset-standards: Requirement Thin offset-like ink layers by using currently developed waterbased inks - mandatory for lamination! High resolution (1.200 dpi plus multi-droplet generated gray scales) Similar optical density / color gamut Pigment water based ink for high light fastness Varnishing and lamination possible (heat resistant up to 230 C) Good peeling resistance (>3N/cm) Where single pass inkjet print (currently) does not meet the offset standards Spot colors as well as white, gold, silver ink (as a matter of time, no technology restriction) Non-printed edges for single-card production today not solved Pretreatment might be required (as with offset) ICMA EuroForum, October 2015 Seite:8
Challenge high pressure on process costs Print TCO similar to anilox offset (estimated ~0,5 Cent / card), process costs much lower, due to: Ink (under development) costs for waterbased inkjet inks approx. on the same level as waterless offset ink No plate costs (inkjet head costs a fraction), no blankets First print ready to sell - (almost) no waste No over or under production Administration (handling costs) for digital print much lower Disadvantage Potentially higher effort for PrePress and automated color management ICMA EuroForum, October 2015 Seite:9
Challange increased security demands Single pass high speed inkjet means fully non-impact printing In theory any fluid can be applied even beyond offset s possibilities feature e.g. like Braille can be covered Disadvantage Assumed insufficient resolution for high resolution features like micro text, Guilloches etc. ICMA EuroForum, October 2015 Seite:10
Challange increased ecological requirements Waterbased inks for single pass high speed inkjet means also VOC free Photoinitiators free Waste elimination Plate / plate cleaning elimation Less energy consumption potentially ICMA EuroForum, October 2015 Seite:11
Conclusion YES! Waterbased piezo inkjet print solutions for cards incorporate the potential of card business improvements due to: Printing costs on approx. same level as offset today, but lower process costs Almost no restriction beside highest resolution Supporting 100% todays market trends High future potential just started, including machine design ICMA EuroForum, October 2015 Seite:12
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