Industrial Single Pass Printing
for Decorative Melamine Surfaces
Carsten Brinkmeyer
Hymmen Industrieanlagen GmbH
Dr. Dieter Holzinger
TIGER Coatings GmbH & Co. KG
PPT-20151005-DGP-Bmc
Outline
Who is Hymmen Industrieanlagen ?
Decorative surfaces industry
Water based or UV curable inks for Single Pass ?
Process comparison with analog printing
Cost comparison with analog printing
Summary
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Hymmen Industrieanlagen GmbH
Double Belt Presses
Who we are:
Family-owned company since 1892
In 4th generation with strong commitment to
new technologies for „continuous production systems“
Production facilities: at 4 places
Technology Center Rödinghausen
Employees: approx. 320
Approx. 10% trainees and dual educated students
Core business in decorative surface industry
Industrial Digital Single Pass Printing machines since 2008
Multi-OpeningPresses
Liquid Coating Lines
Industrial Digital
Printing Lines
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Decorative surfaces industry
Estimation of market size
Paper coated wood-based panel surfaces* (in total 6.5 Bio. sqm)
Interior fittings
5%
Bed & living
room furniture
20%
Office
furniture
20%
analog
94%
Laminate
flooring 17%
Others
8%
digital
6%
Kitchen
furniture
30%
* Source: Munksjö Paper
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Decorative surfaces industry
Most common product buildups (Melamine)
Melamine overlay
Impregnated decor paper
Melamine-faced boards
Wood fibre core layer
Melamine underlay
Backing
Melamine overlay
Impregnated decor paper
Laminates (HPL, Compact)
Phenolic resin paper
Phenolic resin paper
Backing
Most common product buildups (UV-finish)
UV-cured top coat
UV - lacquered boards
Direct printing
Wood fibre core layer
Backing
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Water based or UV curable inks for single pass ?
Water based or UV curable inks ?
Analog printed papers in the market are printed with water based ink.
Water based inkjet printing is already in use for proofing and small batches on
Multi-Pass printing systems.
So everyone is looking for water based digital printing.
But the market requests higher capacities.
The shift in the industry from scanning to single pass systems requires an
strong improvement in system reliability: single pass systems can’t operate
economically with the current levels of nozzle drop out, system down time and
maintenance cycles
Hymmen and TIGER developed a UV-ink for this application
Let’s see why:
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TIGER Coatings GmbH & Co. KG
Who we are:
• Family-owned company since 1930s
• 10 Manufacturing sites on 4 continents
• Global head quarters in Wels (Austria)
• Sales ~ 250 mio €, approx. 1.300
TIGERs globally
• 5th largest manufacturer of powder
coatings worldwide
• BU-TIGITAL since 2010
• Digital business is focused on
industrial applications
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TIGER TIGITAL® - Mission
TIGER TIGITAL® develops and manufactures high performance
industrial inkjet systems based on
• UV curing inks
• Water-based Latex inks & Hybrid inks
• + primer products (powder or liquid)
• + top coats (powder or liquid)
• + clear print varnishes
TIGER TIGITAL sells exclusively to OEM printer manufacturers
and system integrators
• who offer inkjet single pass and
• multi scanning print systems.
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Water based or
UV curable inks for single pass ?
Paper and Substrate
Water based inks
UV-curable inks
Blurred drops on uncoated papers
Sharp drops even on uncoated
papers
Coated paper needed
Printing on uncoated paper possible
Paper growth up to 1,5%
• Paper curling
• Paper wrinkling/creasing
• Registration problems
Paper growth < 0,3 %
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Water based or
UV curable inks for single pass ?
The Inks
Water based inks
UV-curable inks
High amount of solvent components
(60% water + 20% glycol)
Thermal afterburning unit needed
when printing 25 Liter/h
100% crosslinking of all components
VOC-free
(2 m wide printer at 50m/min with 5g/m²)
Suitable for further processing with
melamine
The unique Hymmen ink “Callisto 06“
is suitable for the melamine process
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Water based or
UV curable inks for single pass ?
Drying process:
Water based inks
UV-curable inks
Intermediate curing
UV-LED intermediate curing
Very difficult / not possible
Needed energy for drying is typically
10-15 J/cm²
Needed energy for drying is typically
1-2 J/cm²
High temperature to the substrate
• Shrinking
• Problems with stacking
LED UV or water cooled UV systems
Drying problems on rigid and surface Easy drying on rigid and surface
closed boards
closed boards
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Water based or
UV curable inks for single pass ?
Printing process
Water based inks
UV-curable inks
Reliability in single pass is an big
issue
Verifiable better reliability
Open nozzle time at none used
nozzles is very low
Open nozzle time at none used
nozzles is not an issue
High level of maintenance cycles
needed
Lower level of maintenance cycles
needed
Corrosion protection needed
Corrosion is not an issue
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CPL-production with analog printing
The analog way:
costs
time
order
processing
Decor
printing
externally
at least 1t
time
goods
receipt
costs
time
storage
decor paper
time
stockage of
all decors
impregnation
channel
DBP
mostly only
subsets
rest back
into storage
costs
The CPL manufacturer needs to:
buy more printed paper than needed for one batch
operate an impregnation line
organize his paper stock
PPT-20151005-DGP-Bmc
CPL-production with digital printing
The digital way:
order
processing
JPT
digital
printing
DBP
white paper
storage
The CPL manufacturer needs to:
print only the needed batch
buy only white paper
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Industrial digital printing
The benefits ?
Industrial production of small batch sizes
Embedding of digital printing in process chains
of the decor industry
Individualized mass production
Quick reaction on market trends and customer demands
Shorter "time to market"
New design options (register lengths, colors, depths of detail ...)
Shorter set-up times
No flushing loss
Lower storage costs
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Cost comparison analog – digital printing
Analog printing
product structure
Digital printing
product structure
overlay 22/95
overlay 25/105
+0,02 €
Analog printed paper (impregnated)
digitally printed paper (dry)
- 0,14 €
core paper 80/145
underlay white 70/175
+0,02 €
core paper 160/290
core paper 160/290
+/- 0 €
core paper 160/290
core paper 160/290
+/- 0 €
-0,10 €
Assumption impregnated paper
Basis on 3 t: Printed decor paper
70 g/m²
+ Impregnation process, resins ....
Assumption digital printing paper
White inkjet decor paper - 45 g/m²
Ink consumption 4 g/m²
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Cost comparison with analog printing
Based on the a.m. price assumptions, the following costs will result,
depending on the consumed ink quantity:
1 g/m²
2 g/m²
3 g/m²
4 g/m²
5 g/m²
6 g/m²
7 g/m²
8 g/m²
-0,23€
-0,19€
-0,14€
-0,10€
-0,05€
0€
+0,04€
+0,08€
without valuation
of savings
-0,32€
-0,28€
-0,24€
-0,20€
-0,15€
-0,10€
-0,06€
-0,03€
5% savings
-0,41€
-0,36€
-0,33€
-0,29€
-0,25€
-0,20€
-0,17€
-0,13€
10% savings
Even without financial evaluation of the advantages like
Reduction of storage costs (capital commitment)
Reduction of logistics costs
Material losses impregnation channel
Reduction of the internal processing time
The production with a medium ink application of 6 g/m² is equivalent to the
purchase of analog printed papers with regard to the costs.
PPT-20151005-DGP-Bmc
Summary
The shift in the industry from scanning to single pass systems requires
a strong improvement in system reliability:
single pass systems can’t operate economically with the current levels
of nozzle drop out, system down time and maintenance cycles
UV-Ink is one of the key factors
Hymmen demonstrates with it’s more than 30 installed single pass
printing lines the industrial capability and economic efficiency of
industrial digital printing.
Meet us at hall 6 – booth A31
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Thank you very much for your attention!
Carsten Brinkmeyer
Hymmen Industrieanlagen GmbH
Head of Division Digital Printing
Tel.:
+49 521 5806 144
E-mail: C.Brinkmeyer@hymmen.com
Dr. Dieter Holzinger
TIGER Coatings GmbH & Co. KG
Director R&D Inkjet Inks, PMT UV-Inks
Tel.:
+43 7242 400-1571
E-mail: dieter.holzinger@tiger-coatings.com
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