Industrial Single Pass Printing for Decorative Melamine ... · PDF filePPT-20151005-DGP-Bmc Industrial Single Pass Printing for Decorative Melamine Surfaces Carsten Brinkmeyer Hymmen

PPT-20151005-DGP-Bmc

Industrial Single Pass Printingfor Decorative Melamine Surfaces

Carsten BrinkmeyerHymmen Industrieanlagen GmbH

Dr. Dieter HolzingerTIGER Coatings GmbH & Co. KG

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


Hymmen Industrieanlagen GmbH


� 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

Who we are:Double Belt Presses

Multi-Opening-Presses

Liquid Coating Lines

Industrial Digital Printing Lines

Decorative surfaces industry


Estimation of market size

* Source: Munksjö Paper

Kitchen furniture

30%Office furniture

20%

Bed & living room furniture

20%

Interior fittings5%

Laminate flooring 17%

Others8%

Paper coated wood-based panel surfaces* (in total 6.5 Bio. sqm)

digital6%

analog94%

Decorative surfaces industry


Most common product buildups (Melamine)

Melamine-faced boards

Laminates (HPL, Compact)

Melamine overlay

Impregnated decor paper

Wood fibre core layer

Melamine underlay

Backing

Melamine overlay

Impregnated decor paper

Phenolic resin paper

Phenolic resin paper

Backing

UV - lacquered boards

UV-cured top coat

Direct printing

Wood fibre core layer

Backing

Most common product buildups (UV-finish)

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 applic ation

Let’s see why:

7

TIGER Coatings GmbH & Co. KG

• 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


Who we are:

8

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. PPT-20151005-DGP-BMC

9

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 uncoatedpapers

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 %


10

Water based or UV curable inks for single pass ?The Inks


High amount of solvent components (60% water + 20% glycol)Thermal afterburning unit needed when printing 25 Liter/h(2 m wide printer at 50m/min with 5g/m²)

100% crosslinking of all componentsVOC-free

Suitable for further processing with melamine

The unique Hymmen ink “Callisto 06“is suitable for the melamine process


11

Water based or UV curable inks for single pass ?Drying process:


Intermediate curing

Very difficult / not possible

UV-LED intermediate curing

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 closed boards

Easy drying on rigid and surface closed boards


12

Water based or UV curable inks for single pass ?


Printing process


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

CPL-production with analog printing

orderprocessing

Decorprintingexternally

at least 1t

goodsreceipt

impregnationchannel

mostly onlysubsetsrest backinto storage

DBPstoragedecor paper

stockage ofall decors

The analog way:

costs

time

time

costscosts

time time

The CPL manufacturer needs to:� buy more printed paper than needed for one batch� operate an impregnation line � organize his paper stock


CPL-production with digital printing

orderprocessing

JPTdigitalprinting

DBP

white paperstorage

The digital way:

The CPL manufacturer needs to:� print only the needed batch� buy only white paper


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


Cost comparison analog – digital printing

Analog printingproduct structure

overlay 22/95

Analog printed paper (impregnated)

core paper 80/145

core paper 160/290

core paper 160/290

Digital printingproduct structure

overlay 25/105

digitally printed paper (dry)

underlay white 70/175

core paper 160/290

core paper 160/290

- 0,14 €

+0,02 €

+0,02 €

+/- 0 €

-0,10 €

+/- 0 €

Assumption impregnated paperBasis on 3 t: Printed decor paper70 g/m²+ Impregnation process, resins ....

Assumption digital printing paper White inkjet decor paper - 45 g/m² Ink consumption 4 g/m²


Based on the a.m. price assumptions, the following costs will result, depending on the consumed ink quantity:

Cost comparison with analog printing

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 timeThe production with a medium ink application of 6 g/m² is equivalent to the purchase of analog printed papers with regard to the costs.


� 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

Summary


Thank you very much for your attention!


Carsten Brinkmeyer Hymmen Industrieanlagen GmbHHead of Division Digital PrintingTel.: +49 521 5806 144E-mail: [email protected]

Dr. Dieter Holzinger TIGER Coatings GmbH & Co. KGDirector R&D Inkjet Inks, PMT UV-InksTel.: +43 7242 400-1571E-mail: [email protected]

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Industrial Single Pass Printing for Decorative Melamine ... · PDF filePPT-20151005-DGP-Bmc Industrial Single Pass Printing for Decorative Melamine Surfaces Carsten Brinkmeyer Hymmen