Inkjettechnology:transformingindustrialdecorationDr.SimonDaplyn

Technologypushtomarketpull

Inkjettechnology&marketevolutioncurve:Thenextwavehasstarted

19701975198019851990199520002005201020152020

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