Believe it or not, product coding is crucial for companies involved in industrial packaging or manufacturing. Products must have specific markings like date codes, product batch numbers, QR codes, lot codes, and barcodes to meet distribution network policies and government regulations.
Moreover, the markings should remain clear, easily readable, and legible during the lifespan of a product. Companies require a reliable, effective marking solution, such as Thermal Inkjet Printers, to achieve this.
Also called Bubble printers, Thermal Inkjet Printers (TIJ) are mobile, compact, and capable of producing clear, machine-readable barcodes. They’re widely used for applying necessary codes on product packaging and surfaces.
Compared to other industrial printing machines, TIJ printers are more cost-effective. They cater to the printing needs of small and medium-sized businesses and are versatile and powerful enough to be integrated into larger packaging lines. This article will walk you through everything you need about Thermal Inkjet Printers for coding and marking, including advantages, key features, applications, and more.
What Is Thermal Inkjet Printing, And How Does It Work?
Thermal inkjet printers use electricity or thermal energy to heat ink and apply it to surfaces. They provide affordable high-speed printing on diverse materials.
Unlike continuous inkjet (CIJ) printers which can weigh around 100 pounds, TIJ printers are lightweight and weigh only two to five pounds. You can even use them with manual input.
Despite their compact size, Thermal inkjet printers can produce clear and legible markings on various porous and nonporous surfaces, including barcodes, lot codes, QR codes, and best-by dates.
TIJ printers use disposable cartridges for ink compared to CIJ printers which rely heavily on large refillable bottles. The ink stored in the cartridges is propelled toward the substrate through a process called “drop ejection,” which involves the following four steps.
- The Heater Heats Ink: The ink flows from the cartridge into a chamber, where electronic resistors rapidly heat it at an astonishing rate of 1,800,032 degrees Fahrenheit (1,000,000 degrees Celsius) per second
- Ink Vaporisation Creates A Bubble: Once the ink reaches a temperature of 644°F (340°C), vaporisation occurs, forming a bubble.
- The Bubble Pushes Ink Out Of A Nozzle: As the bubble expands, it propels the ink out of the chamber and through the nozzle.
- Bubble Collapses: When the ink droplet lands on a substrate, the collapsing bubble generates a vacuum effect. This vacuum draws more ink into the chamber, initiating the process once again
The reliable and versatile nature of industrial TIJ printers makes them perfect for various industries and sectors.Â
The Advantages Of Using Thermal Inkjet Printers For Coding And Marking
Thermal inkjet (ITJ) printers are advanced printing solutions that offer numerous benefits to various industries. They create high-quality, durable, and precise legible markings, making them a popular choice for businesses worldwide.
Listed below are five key benefits of thermal inkjet printers for coding and marking that other printers can’t match.
Zero-Maintenance Operation And Cost-Effective
TIJ printers are simple modular systems that employ removable cartridges as an ink supply. These cartridges act as printheads and ink reservoirs, allowing them to operate successfully for years with little to no maintenance.
Moreover, repair costs are limited to cartridge replacement only if there’s any printhead damage. Unlike other printing solutions, thermal inkjet printers’ zero-maintenance approach significantly lowers total ownership costs.
Extremely Versatile
Thermal inkjet printers can code various substrates, including paper, plastics, cardboard, sponge, varnished woods, plaster, metals, ceramics, and more.
They can operate efficiently at around 100m/minute or more speed. This speed and versatility allow industries like food packaging, beverage bottling, chemical packaging, etc., to print effortlessly on different surfaces and expand their product offerings.
High-Resolution Printing
TIJ printers can produce prints with exceptional clarity and resolution of up to 600 DPI, ensuring that text, barcodes, logos, and graphics appear sharp and professional.
This feature is especially crucial in industries where precise labelling and marking of products are necessary.
Eco-Friendly
Unlike some printing technologies that require solvent-based inks, thermal inkjet printers use water-based inks that are more environmentally friendly.
These inks have fewer hazardous components and emit fewer volatile organic compounds (VOCs), promoting a greener printing process.
User-Friendly Operation
Industrial thermal inkjet printers are easy to operate and maintain. They often come with intuitive control panels and user-friendly software interfaces, allowing operators to set up and manage printing tasks easily.
Key Features Of Thermal Inkjet Printers To Consider
When selecting an industrial thermal inkjet printer (TIJ), there are several key features you need to consider to ensure you get the ideal machine for coding and marking.
This will help you obtain a printer that meets your diverse printing demands and has dependable, quality performance.
Here are a few key features to consider
Print Resolution
Print resolution refers to the printed image’s quality, measured in dots per inch (dpi). A higher dpi means a sharper, more detailed print.
Look for high-resolution printers such as 600 dpi, especially if you want to print small fonts, graphics, or logos.
Print Speed
Print speed can affect production efficiency, so choose a printer that can produce prints quickly without sacrificing print quality.
Thermal inkjet printers are known for fast printing speed. For instance, models such as Anser X1 can generate up to 300m/min.
Ink Type And Color Options
Understanding the major differences between various ink types is vital when choosing a thermal inkjet printer, as every type provides unique advantages and potential drawbacks based on your specific coding and marking needs.
Consider the types of materials you will be printing on and choose a printer that offers ink options suitable for those substrates, whether porous, nonporous, or semi-porous.
Automation Level
Automation can help streamline operations and production and minimise the potential for errors. Make sure to choose TIJ printers with features like automatic cleaning and maintenance routines and the ability to adjust print settings automatically based on the material you are printing on.
Connectivity
Whether Bluetooth, Wi-Fi, or ethernet, connectivity is crucial, particularly for companies with several locations or remote workers.
Connecting the printer to a network or the internet can make managing and monitoring the printing process easier.
Choosing The Right Coding And Marking Thermal Inkjet Printer
When selecting the suitable Thermal Inkjet Printer for your business, it’s crucial to consider several factors that align with your specific requirements.
Consider the following factors when making a purchase:
The Substrate You’ll Print On
Is it nonporous? Porous? Is it matte or glossy? These substrate properties help determine the printer and ink required for a durable and legible print.
Thanks to recent advancements in ink technology, thermal inkjet printers can effectively print on numerous surfaces, including glass and metal.
Product Shape
There are two kinds of printers: “contact” and “non-contact.” While contact printers require direct printhead contact with the printing surface, non-contact printers throw ink onto the surface from a distance.
Contact technologies include hot foil and thermal transfer, while contact-free technologies include laser, continuous inkjet (CIJ), and thermal inkjet (TIJ).
For flat products, you can choose either printer type. However, only contact-free printers are suitable if the printing area is curved.
The choice depends on the curvature: slight curves can be handled by thermal inkjet printers, while laser or CIJ printers are better for significant curves.
Print Quality And Size
The print size and quality needed often depend on the packaging type. For instance, the code must be high quality yet discreet when printing on a perfume carton.
The content you’ll print will also affect print quality and size. A company graphic or logo often requires a higher resolution than standard date codes.
Other considerations include scanner/camera readability, print area size, and the amount of information to be printed (e.g., small date or full ingredients).
Printing Volume
Determine the estimated number of prints your business requires per day or month. This will help you choose a printer that can handle your workload efficiently without frequent downtime or maintenance.
Required Print Colour
In most coding applications, black print is usually enough. But sometimes, you may need a different colour, like a white date code on a dark-coloured chocolate box or a yellow part number on a black pipe.
The available colour options depend on the technology used, so if you need anything other than black print, choose a thermal inkjet printer with multiple colour options.
Information To Be Printed
Need to print static data like a part number or logo? Or variable information like batch numbers or date codes?
If you want to print variable information, consider how often it changes. Do you need an auto-updating printer or one handled by an operator?
Environmental Impact
No coding technology is currently fully environmentally friendly or sustainable. However, energy usage, waste generation, and chemical usage vary significantly among different technologies.
Unlike Continuous inkjet printers, thermal inkjet printers use self-contained cartridges that you can safely discard.
Reputation & Support
Research the brand and model of the printer you are considering. Look for customer reviews, reliability ratings, and the manufacturer’s reputation for providing prompt technical support or warranty coverage.
Scalability
Consider your business’s potential future growth and whether the printer can accommodate increased printing demands if your business expands.
It’s beneficial to invest in a printer that can scale with your business needs to avoid the need for frequent upgrades.
Budget
Look beyond the initial purchase price and consider the long-term costs of the printer, including maintenance, ink, and consumables. A printer with a higher upfront cost might prove more cost-effective in the long run.
Maintenance And Troubleshooting Tips For Thermal Inkjet Printers
To keep your thermal inkjet printer running smoothly and producing high-resolution prints, it’s crucial to maintain it regularly.
Here are a few easy-to-follow maintenance and troubleshooting tips for your TIJ printers
Maintenance Tips
- Regular Cleaning: Dust, debris, and ink residue can accumulate on the printer’s printhead and other components. Use recommended cleaning solutions and lint-free cloths to prevent clogs and maintain print quality.
- Printhead Care: The printhead is a critical component that requires special attention. Ensure to clean it periodically as per the manufacturer’s instructions. You can also replace it to avoid print defects and maintain optimal performance.
- Monitor Ink Levels: Monitor ink levels regularly and replace cartridges as needed. Running out of ink can damage the printhead and lead to poor print quality. Always use genuine ink cartridges recommended by the printer manufacturer.
- Follow Maintenance Schedule: Lubrication, belt tension adjustment, and sensor calibration can prevent breakdowns and extend printer lifespan.
- Professional Servicing: If you encounter persistent issues or complex maintenance tasks, it’s best to seek professional servicing. Certified technicians can diagnose and repair any problems to keep your printer running smoothly.
Troubleshooting Tips
By following the below troubleshooting tips you can avoid marking and coding issues that can affect the production or printing quality of thermal inkjet printers
- Poor Print Quality: The dried ink which is present in the printhead nozzles often causes low print quality. This usually occurs when the printer remains inactive for extended periods. To prevent this, it’s essential to regularly purge and clean the cartridge as advised by the manufacturer.
- Cartridge & Ink Failure: Properly storing printer cartridges per the manufacturer’s recommendations reduces the likelihood of failure and extends their shelf life. Disposing of expired ink is crucial to avoid damage to the cartridge or printhead caused by ink degradation. Keep in mind that many inks have a shelf life of one year or less.
- Excessive Downtime: During product changes or production delays, ink can dry on thermal inkjet printheads. To restore ink flow, carefully wipe and purge the cartridges. The ink manufacturer provides the average decap time, which is usually brief. However, unlike other solvent inks, SIGMA solvent ink can remain idle for up to 12 hours.Â
- Printer Doesn’t Print: Thermal inkjet printhead cartridges are highly reliable, but it’s important to ensure that the printer’s sensors trigger timely. Improper sensor alignment can cause the printer to fire too early or too late, resulting in print issues. If alignment is fine, test the system with a different cartridge. It’s better to use factory-new cartridges as they’re more reliable than remanufactured aftermarket or ones.
- Print Speed Problems: The printer’s high speed can lead to quality problems and print misfiring. To ensure successful printing, it is necessary to align the print speed and conveyor settings. Mismatched settings often cause incorrect placement and distorted images. Utilising an encoder can accurately determine the speed settings of print for each product as it passes the printhead.
Applications Of Thermal Inkjet Printing In Various Industries
Thermal Inkjet printers are robust, versatile machines used in a wide variety of industries, including:
Food Packaging
Food manufacturers use different packaging options, including paperboard cartons, metal cans, flexible bags, and rigid cases, to present their products for sale.
By using ink formulations that work well with thermal inkjet printers, food industry experts can effectively label products, preventing any undesirable consequences of ink migration.
Beverage Bottling
TIJ printers print product information, such as manufacturing dates, lot numbers, and variable data like flavour or size variations, on bottle labels, caps, or directly on the bottles themselves.
They offer fast printing speeds, allowing seamless integration into high-speed bottling production lines.
Personal Care Product/Cosmetic Packaging
Personal care products such as hand sanitisers, shampoos, and topical ointments fall within the ambit of the regulations.Â
These over-the-counter pharmaceuticals need to follow regulations and display their monogram, which is printed on the bottle using TIJ printers that fit the available space. Prescription medicine manufacturers also use this method for drug labelling guidelines.Â
Thermal inkjet printers allow manufacturers to create eye-catching labels and intricate designs on various surfaces, including glass, plastic, and metallic materials.
Pharmaceutical Packaging
TIJ printers are extensively used in pharmaceutical packaging to print essential information on medicine packages, blister packs, labels, and vials. This information includes batch numbers, expiration dates, dosage instructions, barcodes, and variable data.
Thermal Inkjet printers ensure precise and accurate printing, meeting the pharmaceutical industry’s stringent quality and regulatory requirements.
Thermal Inkjet Printer And The Future Of Coding And Marking
Thermal inkjet printers have become a formidable competitor to continuous inkjet printers, particularly in marking and coding.
For instance, thanks to innovative printhead advancements by i-mark, it’s now possible to print high-resolution 2D codes, lot codes, and expiration dates on curved surfaces with a 10 mm throw distance.
This breakthrough is a game-changer for companies concerned about ensuring vital food and pharmaceutical packaging information clarity.
Moreover, thermal inkjet (TIJ) printing brings notable environmental benefits. TIJ printers reduce volatile organic compounds (VOCs) by almost 90% compared to CIJ systems.
Not only does TIJ technology deliver a more cost-effective production process, but it also improves the often-overlooked factor of employee health costs.
As a result, the migration towards TIJ printing systems is becoming an emerging trend, particularly within the food and pharmaceutical packaging industry.
With its ability to offer enhanced print quality on curved surfaces, reduced environmental impact, lower production costs, and improved employee well-being, it’s no surprise that TIJ technology is gaining traction among brands in these sectors and more.
Best Practices For Getting The Most Out Of Your Thermal Inkjet Printer
For better efficiency and results from your thermal inkjet printers, consider the following tips:
Store Ink Cartridges Properly
If you have spare ink cartridges, store them in a cool, dry place away from direct sunlight. Extreme temperatures and humidity can affect the quality and performance of the ink.
Update Printer Firmware And Drivers
Periodically check for firmware updates and driver software provided by the printer manufacturer. These updates often include performance improvements and bug fixes that can enhance print quality and overall printer functionality.
Adjust Print Settings
Take advantage of the printer’s advanced settings and options to optimise print quality for different types of documents. Experiment with print modes, colour settings, and print resolutions to achieve the desired results.
Keep The Printer In A Suitable Environment
Place the printer in a clean and well-ventilated area, away from excessive heat, direct sunlight, and moisture. Extreme environmental conditions can affect printer performance and ink quality.
Conclusion
Thermal inkjet printers are one of the world’s go-to industrial printing options—and for various good reasons.
They are small, lightweight, and flexible to fit into different line setups, and their thermal inkjet technology reduces maintenance requirements, leading to higher uptime and lower ownership costs.
It is important to assess the overall costs of Thermal Inkjets as they carry a high ink cost per print but if volumes are low they are still a cost-effective alternative and replacement option.
Some TIJ models use water-based and solvent-based inks to print on various substrates and can produce high-resolution barcodes and QR codes that can be easily scanned.
As versatile, powerful, and cost-effective machines, thermal inkjet printers are attractive to companies that are small and medium-sized and have specialisations. However, due to the extensive range of TIJ printers available in the market, choosing the perfect model can be challenging.Â
Before purchasing, review our helpful guide on thermal inkjet printers for coding and marking to get the best device for your printing needs.