industrial single pass printing for decorative melamine ... · pdf fileppt-20151005-dgp-bmc...
Post on 17-Mar-2018
222 Views
Preview:
TRANSCRIPT
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
PPT-20151005-DGP-Bmc
Hymmen Industrieanlagen GmbH
PPT-20151005-DGP-Bmc
� 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
PPT-20151005-DGP-Bmc
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
PPT-20151005-DGP-Bmc
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 ?
PPT-20151005-DGP-Bmc
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
PPT-20151005-DGP-Bmc
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 %
PPT-20151005-DGP-Bmc
10
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(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
PPT-20151005-DGP-Bmc
11
Water based or UV curable inks for single pass ?Drying process:
Water based inks UV-curable inks
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
PPT-20151005-DGP-Bmc
12
Water based or UV curable inks for single pass ?
PPT-20151005-DGP-Bmc
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
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
PPT-20151005-DGP-Bmc
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
PPT-20151005-DGP-Bmc
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
PPT-20151005-DGP-Bmc
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
PPT-20151005-DGP-Bmc
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.
PPT-20151005-DGP-Bmc
� 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
PPT-20151005-DGP-Bmc
Thank you very much for your attention!
PPT-20151005-DGP-Bmc
Carsten Brinkmeyer Hymmen Industrieanlagen GmbHHead of Division Digital PrintingTel.: +49 521 5806 144E-mail: C.Brinkmeyer@hymmen.com
Dr. Dieter Holzinger TIGER Coatings GmbH & Co. KGDirector R&D Inkjet Inks, PMT UV-InksTel.: +43 7242 400-1571E-mail: dieter.holzinger@tiger-coatings.com
top related