Rapid White Paper 2011

A White Paper by Impression Technology Americas

Comparative Look at Methods of Print
A Label Industry Perspective

Written by

Impression Technology Americas

2011

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


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

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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.

Rapid Label Systems . www.RapidLabelSys.com . 813-549-0796 Page 1


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

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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



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



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



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



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



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.



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:

Laser:
+ Long Lasting Toner
- High Consumable Cost
Offset: Thermal Transfer:
+ High Speed + High Speed
- Limited Variation - Low Resolution

Flexograpic: Low Cost to Buy Traditional Inkjet:
+ High Speed + High Resolution
- High Cost to Own Low Ink Cost - Low Speed

High Speed
High Resolution



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: Sales@RapidLabelSys.com
PH: 813-549-0796
FX: 813-839-2896
www.RapidLabelSys.com



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.


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