Industrial printers deliver exceptionally high print resolution and can generate an extremely high volume of orders at continuous, rapid speeds. Some industrial printers are equipped to handle around-the-clock performance as they are built for durability and are considered low maintenance.
Examples of Industrial Printing Products
Industrial printing is now a common component of a typical manufacturing process. The primary function of industrial printing is to print marketing messages and enhance product value by adding necessary functions. Some examples of industrial printing products would include:
- Apparel Tags
- Wristbands
- Lids
- Sterilization Pouches
- Medical Packaging
- Blister cards
How Industrial Printers Work
Industrial printers are sophisticated machines designed for high-volume printing tasks in industrial settings. These printers employ advanced technologies to produce large quantities of printed materials efficiently and accurately.
At the heart of industrial printers are precision mechanisms that ensure precise alignment and registration of print elements, resulting in crisp and clear prints even at high speeds. One key component of industrial printers is the printhead, which applies ink or toner onto the printing substrate.
These printheads can vary in technology, ranging from inkjet printheads that eject tiny droplets of ink onto the substrate to laser printheads that use lasers to create electrostatic charges for toner transfer. The choice of printhead technology depends on factors such as printing speed, resolution, and the type of printed materials.
In addition to printheads, industrial-grade printers also feature robust feeding and handling systems to manage various types and sizes of substrates. These systems ensure smooth and consistent material feeding, minimizing downtime and waste.
Furthermore, industrial printers often integrate cutting-edge software for job management, color calibration, and quality control, enhancing productivity and print output consistency. The speed, durability, high resolution, and advanced features of industrial printers make them an ideal choice for various industries and applications.
Differences Between Industrial Printers
While all industrial-grade printers are designed for high-volume and high-speed printing, there are differences between them based on their technology and capabilities. Some of the key factors that differentiate industrial printers include:
- Printing technology: As mentioned earlier, industrial printers can use different printing technologies such as inkjet, toner, and thermal transfer. Each has its unique advantages and is suitable for specific applications.
- Print resolution: The print resolution of an industrial printer refers to the number of dots per inch (DPI) it can produce. Higher dpi means finer details and sharper prints.
- Speed: Industrial printers can reach hundreds or thousands of prints per minute. The printing speed depends on the printer type and the print job’s complexity.
- Substrate compatibility: Not all industrial printers are created equal in terms of the types and sizes of substrates they can handle. Some are limited to specific materials, while others can print on various substrates, including labels, foils, plastics, and more.
- Maintenance requirements: Industrial printers are built for continuous heavy-duty use and require regular maintenance to ensure optimal performance. However, some industrial printers may have lower maintenance needs than others.
- Maximum printable area: This refers to the largest size of substrate that an industrial printer can accommodate. Some printers may have a smaller maximum printable area, limiting the types of products they can print on.
- Volume: Industrial printers can handle different volume levels, from small batches to high-volume runs. The volume capacity varies depending on the printer model and the type of materials being printed.
Industrial Printing Benefits
It wasn’t until more recently that most manufacturers utilized industrial printing procedures to streamline and enhance their printing applications due to their substantial advantages that improved their bottom line. These methods have become gateways to industrial printing for many industries, resulting in new, more lucrative manufacturing opportunities.
Some benefits of industrial printing include:
- Simplified and efficient workflows: Production processes can be left unattended due to the little setup time and rare mid-production adjustments of industrial printers. At the same time, projects can be accomplished with shorter time frames, thus reducing labor hours, which results in savings.
- Easy customization for on-demand possibilities: Industrial printers allow for unique and custom requests, making you stand out against competitors.
- Unparalleled printing resolution for large-volume projects: The dependability of industrial printers produces vivid and consistent colors on diverse materials, regardless of the quantity required.
- Rapid turnaround times: Having an industrial printer promises fast completion of projects since it lessens wait times for quicker delivery, leading to increased production.
Industrial printing offers countless benefits across all industries. Consistency and durability under extreme temperatures and conditions rank near the top concerning cost efficacy. Furthermore, DoraniX industrial-grade printers have features that make them adaptable and perfect for printing on flat-laying materials, such as paper, Tyvek, and foils.
Thermal Transfer Printing
Thermal transfer printers are well-received and widely used in industries worldwide. Thermal transfer printing utilizes heated ribbon instead of ink or toner. The heat instantly blackens select paper parts, leaving the desired code, text, or image behind. Therefore, they’re frequently used for printing labels as they are built for durability and deliver high-quality print results.
These printers also don’t require a separate label but can print directly on any relatively flat surface, such as chipboard, cardboard, Tyvek, Mylar, and other materials. Additionally, it can rapidly produce product labels and receipts, but they’re not perfect for every application.
Below is a breakdown of its benefits and limitations:
Pros
- Endless printing capabilities at high speeds and long-life image stability
- Superior durability than its alternate industrial printing solutions
- Most industrial thermal printers are compact and easy to use with minimal long-term maintenance costs
- Produces high-definition and high-quality finished prints at high speeds
Cons
- Restricted or limited usage since they can’t print multiple colors
- Thermal transfer printers are more of a manual process.
- Thermally printed markings are susceptible to damage from aging, chemical exposure, light, heat, and excessive physical contact.
The Significance of Thermal Transfer Ribbon Types
As ribbons deliver various capabilities, it’s essential to note the project’s details before selecting a thermal transfer ribbon. A 50/50 mix of wax and resin are the most common ribbons used in thermal transfer printing, making them ideal for everyday items. It will allow the wax to let the ink sink into the product while the resin helps keep it durable.
Ribbons with a 50/50 wax and resin mix are frequently used for Tyvek and chipboard. Depending on the product’s purpose and user demands, a more durable ribbon may be required to offer outstanding performance and sustainability.
Direct Thermal Printing
Unlike thermal transfer printers that rely on ribbons, direct thermal printing employs chemically treated, heat-sensitive media that blackens when it passes under the thermal printhead. The printheads heat pretreated chemical substrates, resulting in a darkening effect during the printing process.
As neither ink nor ribbons are needed in direct thermal printing, maintenance costs for direct thermal printing are lower. Many industries opt for this method for this reason and other irrefutable benefits of direct thermal printing.
More of its advantages and limitations include:
Pros
- No mechanical and moving parts that need replacements or repairs
- Top-quality, scannable images
- More economical and environmentally friendly since there’s no need to buy or dispose of ribbons and ink cartridges
- Quick and accurate print outcomes
Cons
- Lacks the higher level of durability delivered in the thermal transfer printing method
- Not suitable for non-specialized products since the chemicals the heat interacts with are not found in standard materials
- Expensive direct thermal films and limited availability of label material
- Labels blacken when exposed to extreme heat
Contact DoraniX to Request a Quote
DoraniX industrial printing solutions experts are skilled at answering questions, offering solutions to common errors, and providing general assistance. DoraniX experts can provide quotes based on an analysis of manufacturing needs and requirements.
To request a video demonstration of DoraniX products, please reach out today! You may also request a quote, and we’ll develop a cost-effective solution tailored to your industrial printing needs!