Rapid White Paper 2011

A White Paper by Impression Technology Americas

Impression Technology Americas . 5409 S. Westshore Boulevard . Tampa, FL 33611 . Phone: 813-549-0796

Comparative Look at Methods of Print

A Label Industry Perspective

Written by

Impression Technology Americas

2011


R a p i d L a b e l S y s t e m s . w w w . R a p i d L a b e l S y s . c o m . 8 1 3 - 5 4 9 - 0 7 9 6

Page i

Comparative Look at Methods of Print A Label Industry Perspective Content Page Introduction .........................................................................................................1

Traditional Printing: Methods, Benefits & Drawbacks ..........................................2

Flexographic ..............................................................................................2

Offset .........................................................................................................3

Color Thermal Transfer Printing .................................................................4

Latest Printing: Methods, Benefits & Drawbacks .................................................5

Digital Offset ..............................................................................................5

Laser ..........................................................................................................6

Traditional Inkjet ........................................................................................7

Next Generation Inkjet ..............................................................................8

Conclusion ...........................................................................................................9

References ...........................................................................................................11



Page 1

Introduction With so many options to choose from in the label printing industry one

should be mindful of the advantages and disadvantages of the different

types of technology available. Since the invention of the first printing

press, developed by Johannes Guttenberg around 1440, there have been

many changes. Arguably printing and press technologies have spawned the

growth in every sector of the business world.

With regards to the label industry it is brand identification that we are able

to place a value. Any business that engages to sell a product has some

form of a label placed upon its packaging. This branding is where

companies spend millions of dollars per year on. It is absolutely crucial that

the branded label have the right look, right feel and shape to appeal to our

target audience.

Traditionally it has been commonplace to print quantities of labels using

the flexographic process. Undoubtedly, flexography does have its place in

the market however with technology constantly progressing at a breakneck

pace there are other options available for producers each with their own

benefits and drawbacks.

This paper will examine the different printing options available to label

producers and offer guidelines as to each type of technologies advantages

and limitations.



Page 2

Traditional Printing: Methods, Benefits & Drawbacks

Flexographic Printing:

The first flexographic press was first built in Liverpool,

England in 1890 by Bibby, Baron and Sons. At the

basic level this process has not changed throughout

the years. The image to be printed is first placed on

to a flexible relief plate that carries the ink to the

substrate. Though great advancements in the plate

making print process have been made there is

typically a high lead time for prints made in this

fashion.

Benefits:

Great for printing large runs of a single version of label. If your company produces a

product that does not expire, does not change ingredients or is produced in batch

quantities over 10,000 units, flexography is well suited.

o Attributes:

Uses a plate based method of printing

Widely used for printing on non-porous substrates

Up to 2000 feet of substrate printed per minute

Drawbacks:

Due to setup time being longer than other processes, larger quantity runs are

required.

Variable data printing requires a separate set of plates per version. If the item to

which a label is being adhered requires an expiration date or a batch number, an extra

cost for plates or a secondary process may be required which can lead to higher costs

than other methods of print.

High cost of purchase and ownership



Page 3

Offset Printing:

Ira Washington Rubel first developed the first offset

press for printing on paper in 1903. In 1875 Robert

Barclay developed an offset method for printing on

tin. Offset gets its name from the method to which

an image is applied to a substrate; the image is first

inked on to a roller that then “offsets” (transfers)

the image to a rubberized roller and is then placed

on the printing media.

Benefits:

As with flexography superb cost benefit is

provided with larger, longer runs

Consistent high quality images

Longer printing plate life due to use of

rubberized roller

Drawbacks:

Similar to flexography in that due to the extensive setup time and costs associated

with large quantities per version are required

Variable data is limited by the need of separate plates per version

Lower quality images compared to digital offset, rotogravure and the photogravure

methods




Page 4

Color Thermal Transfer Printing:

Invented by SATO Corporation in the late 1940s

the thermal transfer process is defined by the

use of a heat source to apply an image. There

are two types of thermal transfer printing; one

that involves a ribbon and one that does not. In

the case of the ribbon method; a heated

thermal element is pressed on to a ribbon which

contacts the media. The ribbon is melted

(transferred) on to the substrate. With direct

thermal no ribbon is used; the element is

pressed directly on to the media.

Advantages:

Excellent water fastness

Reliability as there are few moving parts

Drawbacks:

Poor image quality, usually between 200dpi and 400dpi

Ribbon method uses a wax based ink that is prone to abrasion marking

Rarely used for large sized labels

Must stay in dry environments and away from oils as the wax based ink can be

dissolved



Page 5

Latest Printing: Methods, Benefits & Drawbacks:

As with any industry, technology evolves. There are a few technologies that warrant careful

consideration as they are true in fact, changers of industry. As the scope of this paper is from a

labeling industry point of view the focus hereon will be specific types of digital printing. In this

section we examine some of the newer technologies to the market, their key strengths and

weaknesses.

Digital Offset:

As with other digital processes technology is

changing the way the printers conduct business;

eliminating the needs for films and plates. Speed is

increased as well as the added the ability to print

multiple versions of imagery (Sequential

numbering, expiration dates, personalized data

incorporation).

Benefits:

Enhanced speed and image control, combined with variable data make a digital offset

press an excellent option. The cost of purchasing a digital offset press can be in

excess of $500,000. Therefore, it is typically used in higher quantity runs to maximize

the return on investment for the owner.

o Attributes:

No plate or films required for image production

No prepress charges usually associated with digital offset

Targeted Printing

Drawbacks:


Depending on colors and paper stock required a traditional method of offset printing

may be required in addition to digital offset

Limited by maximum web width and weight of stock, 350gsm and <=A3 respectively

Uses proprietary substrates only



Page 6

Laser Printing:

Laser printing is no longer a brand new

technology. You can find it in the majority of

offices around the world. Laser printers have a

low cost of purchase and ownership and

produce an excellent image quality. The laser

printer was invented by Xerox in 1969 by

researcher Gary Starkweather. The printer

works by projecting a negative of an image on

to a charged roller (photoreceptor). The image

is produced by a laser and the light of the laser

removes the charge from the areas impacted by

light. The roller then passes over toner where

the remaining charged areas pick up the toner

for placement on media.

Advantages:

High resolution – Because of how the image is generated laser type devises offer a

high degree of image accuracy

Long lasting toners – Approx 15,000 A4 pages

Drawbacks:

Lots of moving parts – Laser incorporates many moving parts that are not in other

types of print devices. This may lead to higher repair costs and greater down time.

High consumable cost – Not only are toners expensive but there are other parts to

replace such as the fuser and drum

Not cost effective for high volume print runs

Moderately higher Cost to purchase – while not as expensive to purchase as digital

offset, flexo or traditional offset some laser printers can exceed $40,000

Slow printing speeds

Does not print on synthetic or precut substrates



Page 7

Traditional Inkjet:

Traditional Inkjet printing has not been unlike the

desktop inkjet that is at your home. An inkjet printer

is a type of computer printer that creates a digital

image by propelling droplets of ink onto paper.

Mainly developed in the 1950s it wasn’t until the

1990s that the inkjet printer became more widely

used.

Inkjet printers offer the ability to print variable data,

a specific image or specific information that relates to a

customer or product, while eliminating any need for plate

making.

Perhaps the most versatile of all of the print methods is

inkjet printing. While not typically known for high speed or

cost effective longer runs recent developments in

technology, outlined in the next section, have revolutionized

this technology.

Advantages:

High Resolution – in most cases up to 1200 x 1200 dpi

No Plate making – completely digital, no setup time

Variable Data – Ability to print as many variations as needed

Drawbacks:

Slow Speed – Short Runs Only, average speed of 2 inches per second, max of 4 inches

but resolution is compromised

High Consumable Cost – Ink receptacles do not have high capacity to print long run

jobs without the need to be replaced.

Not intended for commercial use but the technology has been adapted



Page 8

Next Generation Inkjet:

Technology advancements such as Rapid Label

Systems revolutionary Memjet printhead have

made inkjet viable for almost any print job in

the marketplace. Unlike traditional inkjet

printers that require the printhead to sweep

back and forth in a horizontal line across the

media to deposit ink, the Memjet printhead is

wider than the media. This means that there is no lag

time. Media can flow under the printhead without

having to stop for the ink to be deposited in a

horizontal line. This offers the user low consumable

costs, variable data integration to print, and a variety of

media substrates that make the next generation of

digital inkjet presses a true competitor in both a high

and low volume print facility.

Advantages:

High speed up to 60 feet per minute

Low cost of ownership and consumable cost

Great Resolution up to 1600 x 1600 dpi

Variety of substrates available including

synthetic

Prints on precut media using a gap sensor or

black mark sensor

There are a wide variety of inkjet printers available, but only the Rapid Label Systems X1 features

Memjet technology. Memjet is a single printhead that is wider than the media to which it prints

so there is no small print head to move laterally across the page width which allows the printer to

print fast. So fast in fact, it is truly the fastest inkjet in the marketplace today.



Page 9

Conclusion:

In conclusion there are a lot of different print options available for you to purchase today. When

you are making the selection of a printer remember that it is not just a printer that you are

buying, it is a process. Each process has its advantages and drawbacks, the ones listed here are

just a few of them. It is recommended that you speak directly with each manufacturer in regards

to their products capabilities and limitations. Anyone in the labeling industry should give careful

consideration to all technologies as part of their due diligence before purchase.

The Rapid Label Systems inkjet line up of Memjet based digital label presses have the most value

for dollar, flexibility in printing, high resolution and lower than average consumable cost. The

Memjet printhead represents the latest leap in an arena that most of the technologies stem back

almost 100 years.

Below you will find a visual representation of where the Rapid X1 fits into the marketplace with

respect to common current technology and their independent competitive advantages:

Low Cost to Buy

Low Ink Cost

High Speed

High Resolution

Flexograpic:

+ High Speed

- High Cost to Own

Offset:

+ High Speed

- Limited Variation

Laser:

+ Long Lasting Toner

- High Consumable Cost

Thermal Transfer:

+ High Speed

- Low Resolution

Traditional Inkjet:

+ High Resolution

- Low Speed



Page 10

It is also important to look at the cost of purchase when making a decision to purchase. Often

time the cost to purchase a piece of equipment can significantly affect the rate at which you will

achieve a true return on investment. For example, if you decide to purchase a flexographic or

digital offset machine you could spend up to and in excess of $500,000. You should take a look at

the volume you would need to run in order to truly make a profit. While high speed digital inkjet

presses may not print labels at the rate of flexographic presses what they can offer is a more

appropriate cost to volume ratio that enables a faster return rate due to their lower cost to

purchase. In some cases it is even more cost effective to purchase several digital inkjet presses

thus increasing total output speed while maintaining the ever important fast return on

investment.

Impression Technology Americas welcomes you to speak to anyone of our representatives about

which technology is right for you. In addition our subject matter experts are here to guide you

through the decision making process, answer all of your questions in addition to making sure that

you are satisfied.

Distributed by:

Impression Technology Americas

5409 South Westshore Boulevard

Tampa, FL 33611

Email: [email protected]

PH: 813-549-0796

FX: 813-839-2896

www.RapidLabelSys.com



Page 11

References:

Fleming, Dan.”Inroduction”. Flexographic printing. Department of Paper Engineering, Chemical

Engineering, and Imaging, Western Michigan University.

Kipphan, Helmut (2001). Handbook of print media: technologies and production methods

(Illustrated ed.). Springer. ISBN 3540673261.

Carter, Rob, Ben Day, Philip Meggs. Typographic Design: Form and Communication, Third Edition.

(2002) John Wiley & Sons, Inc.

"Particle Emission Characteristics of Office Printers". The San Francisco Chronicle.

"Facts about laser printing(access date 2010-09-01)". Papergear.com. 2010-09-01

Edwin D. Reilly (2003). Milestones in Computer Science and Information Technology. Greenwood

Press. ISBN 1573565210.

Rapid White Paper 2011

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