transforming industrial decoration - sensient · §inkjet printing difficult materials §pigments...
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Inkjettechnology:transformingindustrialdecorationDr.SimonDaplyn
Technologypushtomarketpull
Inkjettechnology&marketevolutioncurve:Thenextwavehasstarted
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Marketsize
TechnologyInnovation
TechnologyInnovation
TechnologyInnovation
MarketDevelopment
MarketDevelopment
MarketDevelopment
DateCodingDirectMail
CADGraphics
SOHO
PhotoLabels
PackagingFoodTextiles
CeramicsFlooringWallCoverings
Penplotters
E-stat
Cutvinyl
Screenprint
DigitalPrinting– TheBenefits
§ Increasedefficiency.Reducedproductioncosts§ Increasedproductivity§ Fasterresponse.Just-in-timecustomisation§ Zerosetupcosts.Cost-effectiveshortruns§ Reducedinventory§ Idealforalltypesofsubstrates§ Idealformanyapplications
Inkjetformanufacture
§ Useinkjetto:§ Coat§ Createmanufacturingprocesses§ Manufactureproducts
§ Inkjetprintingdifficultmaterials§ Pigments(includinginorganic),phosphors,metals§ Polymers§ Functionalmaterials
§ Keyinkjetinktechnologies§ Pigmentandpolymerdispersion§ AqueousandUVcurechemistries
Inkjetdepositionofcoatings
Productioninkjetcoatingdepositionrequires
§Highthroughput§Highreliabilityà highproductivity§Excellentinkchemistry
§ Functionalperformance§ Reliableprinting
§Costsmustmakesenseforapplication
Laminatesmarket
§ DecorativeLaminatesMarketsizeisestimatedtosurpass12billionsquaremetersby2023,growingatmorethan5.5%CAGRfrom2016to2023
§ SalesofdecorativelaminatesestimatedatUS$40.8bn2by2018§ AsiaPacificsalesaccountforover46%oftheglobalrevenuein2015§ Furnitureandcabinetswasthelargestsegmentin2015andaccountedformorethan65%oftheglobaldecorativelaminatesmarketshare
Source:EPLFannualPressConference,DOMOTEX2016
Laminates- marketdrivers
§ Currentlydominatedbyscreenandflexo
§ Driverstowardsinkjet§ Movebeyondcommoditydesigns§ Experimentalfashions§ Customisedsurfaces– logos&murals§ Customisationandshortruns
§ Marketrequirements§ Flatbeddigitalprintingofrigidfurnishingsupto1.5x1.0m
§ UVink§ Continuousprintingofflexiblelaminatefilms/decorpaper(width?)
§ Solvent/aqueousink
LaminateStructure
§ Laminatefloorshaveathree-layeredstructure:§ Decorativepaper+overlay
§ Layerconsistingofsheetsimpregnatedwiththermosettingresins,pressedusingthreedifferenttechniques:
§Highpressurelaminates(HPL)§ Continuouspressedlaminates(CPL)§Directlypressedtothesubstrate(DPL)
§ MainCore(typicallyMDForHDF)§ Stabilisinglayer(backing,typicallyHPLorCPLimpregnatedpapersorvaneers)
Fastness Requirement
Mostcustomershavespecificrequirementsforeachproducthoweverasimpleoverviewofatypicalsetofproductspecificationsisgivenbelow:
AsoutlinedinEN13329,“Laminatefloorcoverings.Specifications,requirementsandtestmethods”.IndustrystandardtestisEN438highlighted.
Characteristic Requirement Test Method
Light FastnessBlue wool scale, part B02, not worse than 6 EN ISO 105
Grey scale, part A02, not worse than 4 EN 20105
Abrasion resistance AC1-AC5 depending on usage level/market(domestic/commercial)
Taber test (Taber S-34)
Resistance to staining 5 (Groups 1 and 2)4 (Group 3) EN 438
ModularApproach
§ Restrictedimplementationofdigitaltechnologyduetodisruptivenature§ Digitalprintingcarriedoutoffline
§ BatchorrolltorollprintingàLoadontocoatingline
§ Useofmodulesallowsdigitaltechnologytobeconfiguredoverexistingproductionline
§ Ontheflyproductionandcorrection§ Samplingonproductionsystem§ Improvedcolourandprintconsistencyforsamplescustomers§ Reducedfootprintrequirement
SinglePassPrinting
§ Fixedarrayofheadsacrosstheweb§ Madepossiblebyadvancedreliabilityofinksandprinthead§ Increasedthroughput§ Currentlylimitedwebwidthbutwillincrease
Ceramictilesproduction
§ Widestadoptionofdigitaltechnologyforproductionsolution§ Over200systemsinstalledinChina§ Revolutionisedceramicdecoration
§ ReducedCost§ SimplifiedProcess§ ReducedMaterialsConsumption§ EliminationofRepeatDesign
Ceramicsmarketneed
§ Marketrequirementforceramictileprinting
§ Printingsystem§ Highproductivity(>900m2/hr)§ Highreliability(>98%uptime)§ Costeffective§ Highquality(300+dpi,greyscale,)§ Goodcolourperformance(4+colours)
§ Inks§ Excellentcolourperformancewhenfired§ Goodreliabilityinsystem§ Loweroperatingcosts
Inkledsolutions
§ Understandinginkchemistryvital§ Interactionwithsubstrate§ Interactionwithsystemcomponents§ Compatibilitywithprocess
§ Temperatures§ Lamination§ Porosityrequirement
§ ProductionControl§ Batchtobatchconsistency:§ Colour§ Physicalproperties
Integration– thekeychallenge
Encoder/productdetect
Wetting,drying,curing Fluidcontrol
Driveelectronics,software
Substrate Printheads
Inkchemistry
Motionsystem
Inkcomponents
Liquidcarrier
Binders/bulkmatrix
Rheologymodifiers
Functionalmaterials
Colorants
Surfactants
Adhesionpromoters
Otheradditives
Inkformulation
UVcurablePhasechange
Oil-based
Solvent-based
Aqueous
Inks
SubstratePorous
Paper
Textile
Ceramic
Non-porous
Polymer
Metal
Glass
PropertiesAdhesion
Scratchresistance
Lightfastness
Flexibility
ProcessLinespeed
Quality
Reliability
Environment
CustomerSpecification
Inktesting– JettingandWetting
Inkperformanceeffectedbyformulation,jettingconsistencyandsubstrateinteraction
Importanceofformulation
Goodink
Nonidealink
Effectofdropformationonprintquality
Summary
§ Digitalprintingofdecorativesurfacesaverypromisingapplicationwithgreatmarketpotential
§ Keymarketdriversforbespokedesignsandshorterruns§ Technologychallengesneedtobeunderstoodandaddressed§ Importanttodevelopspecificsolutionsforparticularapplications§ Adoptiondependenton:
§ Specificinkchemistriestomatchapplicationrequirements§ Inlineprintcapability
§ Technologyisavailablenowtodrivemarketadoption§ Successwillbedeliveredthroughcollaborationoftechnologyenablersandmarketleadingproviderstogiveoptimisedapplicationperformance