Inkjet Printhead for Corrugated Packaging

Inkjet technology group Xaar is changing corrugated packaging printing, delivering flexo quality and a reduced cost per print alongside digital customization and personalization benefits in a single pass.

Thanks to Xaar’s Ultra High Viscosity Technology, its Aquinox printhead can jetfluids of up to 1000 centipoises (cP) at ambient temperature (approx. 100 cP at jetting temperature), which has allowed chemists to develop inks that overcome many of the barriers inkjet has previously faced in the corrugate sector. These high viscosity formulations minimize ink absorption into corrugated surfaces to produce opacity and color vibrancy, ensuring both visible appeal and durability for corrugated packaging.

By absorbing less ink into the board, the same print quality is achieved with less ink, enabling faster printing and reducing production costs as well as the total cost of ownership. Printing with the water-based high viscosity inks developed by Nazdar meets the demands of the fastest corrugated packaging production lines. 

In addition, with less substrate penetration, high-viscosity inks can remove the need for primers, simplifying the printing process and improving sustainability by reducing drying energy and fluid usage – resulting in brighter, more vibrant prints on uncoated and unprimed corrugate boards. Xaar’s technology also decreases cost per job alongside delivering flexo-level print quality.

Independent research conducted by the Welsh Centre for Printing and Coating at Swansea University demonstrated that using Xaar’s Ultra High Viscosity Technology increases color density by up to 60%, expanding the color gamut and boosting productivity. In addition, by reducing water in the inks, less energy is consumed in the drying process, lowering operational costs and aligning with corrugated packaging manufacturers’ sustainability goals. 

The Xaar Aquinox’s higher throw distance prevents substrate-induced damage through collisions with the printhead, and accommodates varying gauges of cardboard. Xaar’s TF Technology eliminates potential nozzle blockages from cardboard dust, and fast printhead recovery minimizes ink waste and downtime during production starts and stops. Optimal ink conditions can be maintained throughout long print runs by a Megnajet fluid management system ensuring uniform print quality when using high viscosity inks. 

Xaar’s Business Development Manager, Neil Cook said, “Historically, inkjet printing has not been able to provide the quality, reliability or speed that corrugated packaging print required. Now, thanks to our Ultra High Viscosity Technology, we can deliver the high print quality standards demanded while reducing the cost per print.”

Xaar is focused on building inkjet’s growth within the corrugate sector, highlighting its benefits to attract more customers. Neil said, “Alongside the intrinsic advantages of customization available from digital print, with its impactful colors, reduced cost per print and sustainability benefits, Xaar Technology is providing a game-changing shift in corrugated printing. This innovation is redefining what’s possible for users, unlocking new opportunities in print and setting a new standard for the industry.”

Learn more about Xaar’s corrugate printing technology.