by [TC]²
A monthly column of technology rambling, rumination and reality
By: Jud Early, Corporate Vice President, Research, [TC]²
July 2005
Hello, faithful readers,
Don't be alarmed. It really is August, this column is just being posted late. Please pardon the tardy arrival. While I'm in a mea culpa mode, I need to let some of you know that due to an internal routing problem with some of the “Ask Jud” e-mails, I am also behind in responding to your questions. Again, I ask your tolerance as I dig out from the backlog. Each one will be answered soon.
My last writing came to you from Munich Germany, where I was attending FESPA, the Federation of European Screen Printers' Associations Trade Show. In describing the show, it can be said in one word- BIG. Occupying four halls at the Munich Trade Fair exhibition center, the show, was titled “The Future Of Digital Imaging” and with more than thirty thousand visitors in the aisles, was really a big show.
Entry Hall for Munich Exhibition Center
Site of FESPA 2005
About two-thirds of the exhibit area was devoted to screen printing and graphic arts. Numerous large-scale printers were set up and in operation. Media vendors enjoyed a lot of space, software and RIP vendors were well represented, and of course the focus of this report, digital printers and related equipment. With more than 500 vendors from forty-six countries exhibiting, I carefully planned my routes and schedule, since it would be impossible to meet with all. My interest was predominantly for textile printing.
Arriving in the afternoon of the first day, I walked the four halls, noting where key exhibitors were located, and locations of restrooms, food service and information. In order to report on items other than digital print for textiles, I began the next morning in Hall A1 where screen printing systems were located. Also in this hall were our friends from Stork Prints and from Studio FX which we will discuss more fully in this review. Companies from the US were exhibiting ink and screen processes. Hall A2 was more of the same, with a concentration of apparel companies, suppliers of blanks for the imprinted tee-shirt sector. Sara Lee, Fruit of the Loom, American Apparel all were showing knitwear of all types. There also were European suppliers as well as manufacturers from the Far East. About half of Hall B1 contained media suppliers and some large flat screen machines, with the balance given to digital printing which carried over to the entire Hall B2. These four large halls were separated by a courtyard about one hundred meters wide, where food services were set up, and tables with umbrellas allowed those lucky enough to get a seat while eating.
Photographs were taken only with permission. Some vendors were quite open and allowed photos, while others did not, and I respected their prohibitions. As a result, some of the descriptions will be in word only. I hope that I will be able to impress upon you the scale of some equipment.
Graphic Arts Machines
The machine for textiles introduced by Reggiani at ITMA 2003 In Birmingham England was not present. You may recall that the machine was an alliance between Reggianni, CIBA and Aprion, who supplied the print engine. A machine was shown at FESPA for printing corrugated board was built around the Aprion print engine. Obviously, the sheet handler and feed advance were different, but the print engine appeared to be the same. The machine picked up one ply of corrugated from a stack of approximately four feet high, separated it from any hanging fibers at the edges, and positioned it for printing. It was then advanced through the engine by a series of walking grippers which slid the sheet a precise distance and after several advances, the sheet was stacked off to a table that lowered as each successive sheet was placed on the stack of finished goods. It was impossible to get accurate information with crowds, noise and language, but it was quite an impressive machine, and produced print with no noticeable banding and very good resolution.
Luscher, a German manufacturer showed the JetPrint that had a huge traveling beam, spanning a large print platen. In this machine, the head traverses the width of the platen as the beam moves along the platen's length.
Looking down the length of the traveling print head beam
View from front side of JetPrint
Inca Digital Printers Ltd. of UK showed the UVJet, another printer for large format. In this machine, the head traverses the width of the platen in similar fashion to the JetPrint, but the platen is moved under a stationary beam. The speed is quite fast, covering the print area in just a minute or so. Here, you can see the platen in motion as printing is taking place. The first band of print is evident along the edge of the media on the near side.
The Inca UVJet with platen in motion
Nur exhibited the Expedia 5000, a grand format machine with capability of up to 150 square meters per hour. Please note the heavy structure that is required to support a printer of this width.
Note the rugged structure of the Expedio 5000
Expedio 5000 from the head side –Note UV curing lamp
Spuhl introduced the 3.5 meter width machine that is produced in Switzerland. This machine, although shown as a graphic arts machine, is what I would term a cross-over machine. It can print graphics on anything up to seven centimeters thick. From paper to cabinet doors, this machine can produce brilliant graphics with UV inks, cured by a lamp system that is carried with the print head. Although the machine shown did not have a fabric handling mechanism, a version of the machine that is built by Leggett & Platt Digital in the US prints textiles with an amazingly soft hand. Draperies, bedspreads and comforters all can be coordinated with color and design.
The Virtu Plus
Siasprint had one of the largest screen printers at the show. The Multiformula is available in one to five colors, and ranges in length from fifty-seven feet for a two color machine to one hundred seven feet for a five color. Catwalks allow access to the opposite side without walking around. Also available with dryer and stacker.
Siasprint Screen Printer from Italy
OK, I believe the point has been made. It was a really big show with several really big machines.
Digital Textile Machines
As one would expect, DuPont exhibited the Artistri, the dual beam machine developed by Ichinosi and marketed by DuPont in many parts of the world. Dupont continues to build its marketing and distribution network for this machine. I will not reprint the photo since it has appeared in several past columns.
Another machine with dual beam construction was on display at the D-Gen stand. D-Gen president & CEO, Kilhun Lee was kind enough to show the Herecle machine's features, and granted permission for photos. The machine is rated for more than 500 square meters per day. Design also is intended to permit a refitting of print engines to the base machine, allowing reuse of the blanket feed mechanism along with its washing system when faster engines become available.
The D-Gen 740TX/C, a cylinder fed machine, and the Artrix, essentially the same machine with a blanket belt were on display. These machines were covered in our ITMA 2003 column, so photos will not be repeated here. The D-Gen Telios machine is touted to be the world's first sublimation printer. This machine, capable of using disperse, acid, pigment and reactive inks, can print sublimation inks directly onto synthetic fabrics, then, in a sublimation section, heat is applied to complete the print. No pretreatment is required, nor is subsequent post treatment.
D-Gen Herecle Dual Beam Textile Printer
D-Gen Herecle view from side
D-Gen Telios Sublimation Printer
ATP Color also exhibited a dual beam machine. Coupled with a blanket belt with integrated washer, the Tinta 8728 is reported to produce 35 square meters of fabric per hour at a resolution of 720 dpi. This innovative Italian developer also showed the “M” series machine, which was tooled for the simultaneous printing of three tee-shirts. The shirts are loaded off-line, with the platens holding the shirts quickly exchanged for the finished platens. The platen for three shirts may be exchanged for a single, large size platen for printing larger images on textiles. Also on display was a printer for the flag and banner business, which prints directly onto the fabric using sublimation inks, passes the fabric through a sublimation station with no subsequent processing necessary.
ATP Color's Tinta 8728 Dual Beam eight color machine
MS machine, another Italian developer of printers, steamers and web tentering systems showed several printers. The MS Jetprint is really a fabric handling system, allowing the customer to specify which of the major print engines to be fitted to the fabric transport. The long heritage of MS in the manufacture of conventional printing machines, has enabled them to use mature technology for fabric transport, while digitally printing using the best technology for the purpose. Also on display was the MS-Coat & Print, a machine that should improve conditions for the digital print house. Containing a pretreatment section, along with a dryer, the machine can be used with pretreated fabrics, or can apply pretreatment to untreated fabrics, and can optionally dry or partially dry the pretreatment to allow printing wet on dry, or wet on wet. Several people commented on the successes they were having when printing on a still-wet fabric. The machine also has a dryer following the print station. The Coat & Print can also be directly coupled to a mini-version of the MS steam ager. When configured thus, a non-treated fabric is loaded onto the printer-coater, pretreatment applied, print image applied and dried, followed by steaming and drying of the web. Finished rolls of printed fabric is output.
MS – Coat & Print
MS Coat & Print SG Plus – the integrated digital processing line.
A relative newcomer to the digital printing scene, Peter Hollanders was a delightful person to interview. As an engineer, the pride in his personal design could not be hidden. Much of what he told me was one engineer speaking to another, and many of the design features will not be revealed here. As each of the new and innovative ideas was described, I asked if it was OK to publish.
Peter requested that certain items not be revealed in this column, but I'm convinced that a serious customer will find a number of ideas that are based on ease of use, reliability for long run printing, and solutions to identified problems that confront digital printers each day. Originally designed for the flag and banner industry, the machine can now print on a diversity of textile materials, and can employ pigment, acid, reactive, disperse and disperse transfer for sublimation printing. The user may obtain inks from any qualified supplier and is not tied to the machine manufacturer for inks. The photo below showing the rear of the machine should be telling. The fabric roll is not visible. Why? It is enclosed in a cabinet to control lint that could foul the print heads. Ink containers hold five liters per color, enough ink to operate continually for fifteen hours at one hundred percent coverage. Normally inks will last as much as a month before refilling. The ink system is constantly recirculating, reducing the chance for sedimentation, and allowing ink refills while operating. Special provisions in the area of printing ensure complete penetration without the danger of smear or false strike-through. Fabric feeding and tensioning is controlled by carefully synchronized servos, enabling very light, wispy fabrics to be run, as well as heavy weight non-stretchy goods. Ruggedly built, the pricing of this machine may place it out of the reach of some, but the durable, reliable design, coupled with numerous innovative features will allow unattended printing overnight, or for a multiple machine plant, a minimal amount of maintenance time.
Hollanders Color Booster Front and Back View
The Mutoh stand displayed a new printer for textiles, the ViperTX. Unfortunately, the staff in the Mutoh booth could not find the person who was knowledgeable about the new machine. After a wait of more than one hour, and repeated trips on subsequent days, it appeared that the expert was not in attendance. After reporting from ITMA 2003 on Mutoh, I received an e-mail from a technical representative stating that I had reported incorrectly with regard to the machine then being shown as being sublimation only, a statement noted while in the Mutoh ITMA stand. Not wanting to repeat any misinformation, I will direct your inquiries to Mutoh.
As mentioned above, digital printing of tee-shirts was seen as a growing area of development. Several developers had machines on display. Below are a few of the more interesting ones. U.S. Screen printing Institute showed a bevy of machines, ranging from a printer to print one shirt at a time, to a ten or twelve shirt platen sized printer. Note the photo below right, the platen table is on casters and rolls away for off-line loading while an alternate platen table is being printed. Machine at left below does not have removable platen table.
Fast Jet printers from U.S. Screen Printing Institute
Colorprint of Italy had several versions of its Micro Logica digital printer for tee-shirts. Simplest form is shown at bottom of photo collage below. It is a printer that can be moved over a platen that is loaded while the printer is stopped. The upper right photo below shows the Micro Logica print engine on a servo controlled slide that is attached to a screen printing turntable. Six paddles on the turntable afford a load station, an unload station, and three screen printing stations in addition to the digital print station. In operation, a shirt is loaded onto one of the paddles and the paddles are indexed by the turntable, presenting an empty station for loading, and the just-loaded paddle to the first screen print station. The screen printer applies the first color to the shirt. Upon indexing, the shirt is printed with a second color, or may have an adhesive screened onto its print area. The index again presents the shirt to the next screen printing station, and after one more index, the paddle is positioned to allow the digital printer to advance for printing the changeable information that will be printed in areas left open by the screen process. In this way, the main part of the shirt can be printed with a fixed design, while at the same time, a variable design, logo, name or other unique symbol is digitally printed. The print is somewhat course at 60 dpi, but at that speed, one hundred shirts can be printed per hour. Another unique feature that was being done was the addition of glass fragments to a bed of adhesive. The effect was very unusual, sparkling as light hit the many different particles, as the digitally printed section complemented the applied glass.
Micro Logica modules by colorprint
Mimaki showed the GP-604 tee-shirt printer, a machine that had been introduced at ITMA 2003, but now appears to be a production machine. The GP-604D, the “D” stands for “discharge”, has a special ink that removes the color from a dark colored shirt, allowing colors and white to be printed on dark colored substrates. Both machines use a special textile pigment ink.
Mimaki GP-604
Kornit, an Israeli company introduced two tee-shirt printers at FESPA, a single platen and a two platen machine, both of which use solvent based inks. This is almost unheard of in textile printing. According to spokesman for Kornit Sarel Askenazy, the machines have six print heads, two for white and four for colors. When printing white or light colored shirts, the 931D can produce 300 shirts per hour. As dark textiles are printed, production slows to 120 per hour. The process for colored substrates is to first lay down a white base upon which to print the colors.
Kornit 730 and 731
DuPont introduced a large format photoprinter that produced eye-popping results. With glossy images up to two meters wide, the resolution was phenomenal. The design and construction of the machine was excellent. According to a DuPont spokesperson, the engineering and manufacturing was all done in China, at a location that was only twenty-five miles from another DuPont facility. The decision to partner with a Chinese company certainly yielded a great result.
StudioFX, a French company, has developed a pre-treatment machine that utilizes heads from Printos of Belgium, a Videojet company. The valve-jet heads are capable of very high operational rates, and seem well suited to the application of controlled amounts of pre-treatment solution to fabrics intended for digital printing. The prototype machine was at the show, and had been completed just the night before transporting to Munich for the show. In addition to the application, a drying section and re-roll of the fabric completes the machine. This interesting company also offers a line of calendars and steaming equipment for fixing digitally printed inks. They also offer software for unique printing situations, and was displaying large beach umbrellas with continuous engineered designs crossing all the gore seams that stitch the umbrella together. The work was beautiful and perfectly matched.
In addition to the machines described above, several developers showed concept machines, but most were for the graphic arts industry. From flat platen machines for corrugated printing, to small machines that deposited resin to create three dimensional buttons and seals, machines that cut and machines that were used for preparation of screens, the show certainly demonstrated the present capabilities and hinted at things to come.
Halls B1 and B2 were set up with a seminar presentation area in each. For three days, topics focused on a number of interests were offered. I had marked the date and time of several seminars that I wanted to attend. It affords a time to take a load off of tired feet, while learning, so I attended at least one each day. By Saturday, with rain outside and the beginning of a sinus infection, I almost decided to sleep in but forced myself to get up and go once more to the show. I wanted to hear a presentation on “Radical Developments In Ink Jet” to be presented by Xaar. It was slotted for the 14:00 to 15:00 time and was the last seminar before the show closed. It would have been so easy to just walk to the subway and go back to the hotel. I'm so glad that I didn't.
The presentation was dynamite. Steve Temple of Xaar told us about the HSS1 head. Many of the slides were marked “confidential” and the few attendees were privileged to learn about the Hybrid Side Shooter technology. Taking a very different approach, the head will operate up to 100 KHz. In a normal ink jet head, air bubbles can come out of the ink and cause missed droplets. In the HSS1 ink is recirculated through a channel that is pressurized and is temperature controlled. At shut down, the ink is permitted to drain back and air enter the head. This would cause no end of startup problems with a conventional design, but upon starting the HSS1 head, the pressurized ink supply quickly fills any air space in the head expelling air and is ready to shoot. The piezo structure is a common wall, but instead of flexing the wall and preventing the adjacent channel from firing, an acoustic wave is set up which ejects the droplets. Each nozzle can fire subdrops as small as three to six picoliters, which can be increased by sixteen levels to a drop size as large as 48 or 96 picoliters. The head has been designed for packaging, electronics, and textiles. Color is easily changed by flushing the drained ink channels, and switching to alternate inks. The internals are coated with a substance that resists all known chemicals, permitting the use of inks that are damaging to unprotected head constructions. Merging of up to seven microdroplets eliminates the artifacts that occur with satellite drops. The heads are gangable into several configurations. Mounting of the heads is done at two points, with a registration system that ensures location consistency within two microns after removal and replacement. This is hard to believe and is quite an accomplishment. The nozzles are drilled by laser after mounting the head with blank nozzle plate to a fixture. By producing holes relative to the registration surfaces, the nozzle position can be ensured and heads replaced without an alignment procedure.
A very impressive motion picture was shown, in which a tap from a technician's wrench did nothing more than to interrupt the print for a fraction of an inch, but no cavitation or drop-out was seen, after several of these purposeful attempts to cause failure.
The Xaar production of 24 million nozzles per year, coupled with more than 120 million produced by their Japanese partner, exceeds the production of what is believed to be the world leading nozzle producer, Hewlett Packard, according to Steve Temple.
As bad as I felt while at the show, the Xaar presentation made the day. I was energized by the news of the radical new design, and am looking forward to seeing them in production printers.
This concludes the FESPA Review. Thanks to all who provided input and shared your time with me.
For August I promise a shorter column, and a guest article that I'm sure will interest you. Until then, be safe in your every action.
Jud