Printing on Flexible Packaging

Across a number of industries, flexible packaging stands as one of the most valuable and frequently used substrates on the market today. An umbrella term used to describe a range of packaging forms constructed from plastic, paper, aluminum foil, coated paper, or film, flexible packaging is valued for its cost-effectiveness and ability to prolong shelf-life. As such, bags, pouches, packages, and cartons made from flexible packaging are commonly found throughout the food industry, beverage packaging, pharmaceutical development, and personal care/cosmetics, among others.

Whether a company is producing bagged snack food or pharmaceutical blister packs, both supply chain guidelines and federal regulations require them to place traceable codes and markings on their products.

Required codes frequently include:

Expiration/best-by-date codes
QR codes
1-dimensional barcodes
2-dimensional barcodes
Data matrices
Serial numbers
Lot codes
Batch numbers

If these codes are missing, poorly placed, or contain incorrect information, companies may need to perform costly recalls, pay penalties, risk bad publicity, and/or sour supply chain relationships. Fortunately, industrial Tetra Pak printing isn't difficult when you have the expert help of InkJet, Inc.

By offering an array of quality printers and diverse ink options, InkJet, Inc. can help your company ensure traceable markings are placed properly and consistently.

Fortunately, industrial printing on flexible packaging isn’t difficult when you have the expert help of InkJet, Inc.

Flexible Packaging Printing Solutions

InkJet, Inc. has more than 30 years of experience in the industrial printing market and can help your company with its flexible packaging marking needs.

This table lists our various flexible packaging printing systems and their general specifications. More information on each machine can be located below. Click the title in the table’s leftmost column to jump to a specific solution.

Coding Technology	Operating Method	System Options	Maximum Resolution and Print Height	Maximum Marking Speed	Cost Factors	Compatible Materials
Continuous Inkjet Printer	Propels pressurized ink droplets towards the substrate	DuraCode Touchscreen, Keyboard, & Pigment	70 DPI at 15 mm height	320 m/min.	Low to moderate unit cost, low consumable cost	Metals and plastics
Thermal Inkjet Printer	Uses heat to pressurize and eject ink droplets toward the substrate	Anser U2 Models	400 x 300 DPI (height varies by model)	76.2 m/min	Low unit cost, moderate consumable cost	Metals, plastics, other materials
		Anser A1	600 x 600 DPI at 1” height (2” height with stitched print heights)	300 m/min with HP cartridges, 150 m/min with IUT cartridges	Moderate unit cost, moderate consumable cost	Metals, plastics, other materials
		Anser X1	600 x 600 DPI at 1” height (2” height with stitched print heights)	300 m/min	Moderate unit cost, moderate consumable cost	Metals, plastics, other materials

Continuous Inkjet Printers: DuraCode Touchscreen, Keyboard, and Pigment

Continuous inkjet (CIJ) printers are non-contact production line printing systems designed to mark substrates moving at up to 300 m/min. Thanks to powerful ink circulation systems, CIJ printers can operate up to 24 hours daily without downtime. The speed, wide ink compatibility, and versatile printheads of CIJ printers allow users to mark thousands of products a day with highly legible codes.

InkJet, Inc. carries three CIJ systems:

All DuraCode systems can mark porous and non-porous substrates at speeds up to 320 m/min. Equipped with an IP55 outer structure and able to operate in temperatures ranging from 41-113° F, the DuraCode CIJ can withstand potentially hazardous environmental elements to deliver consistently excellent results.

The DuraCode Keyboard and Touchscreen offer the same specifications and compatibility with ink formulas. The only difference between them is their input medium. The DuraCode Pigment has identical specifications as the DuraCode Keyboard and Touchscreen but uses pigmented ink instead of dye ink.

See the chart below for a closer look at the DuraCode models’ most important specifications.

Specification	DuraCode Touchscreen, Keyboard, & Pigment CIJ Printers
Nozzle	40, 50, 60, 70 μm
Print Height	1.2-15 mm
Maximum Print Speed	Up to 1,050 ft./min (320 m/min)
Print Distance	1-3 in. (25.4-76.2 mm)
Input System	Touchscreen or Standard Keyboard / WYSIWYG
Print Font	5x5, 7x5, 9x6, 11x8, 16x11, 24x17, 32x22
Operating Environment	Temperature: 5-45° C (41-113°F) Humidity: 0%-90%, no condensing
User Defined Field	Bar Code, QR Code, Logos, Clock, Counter, Classes, etc.
IP Rating	IP55 Industrial Protection
Gross Weight with Complete Package	45 kg / 99 lbs
Standard Features	Font library - Multi-language support - Traverse printing - 90-degree vertical printing - Special counter Counter replacement - Clock replacement - Encoder port - USB port - Ink recovery pump - Solvent flush pump - Micro print
Optional Add-Ons	Serial port - Network LAN connection - Positive air pump

Thermal Inkjet Printers: Anser U2, X1, and A1 Models

Thermal inkjet (TIJ) printers are smaller, lighter, and more cost-effective than CIJ systems. While CIJ systems typically weigh around 100 lbs and can cost around $10,000, most TIJ models weigh 5-10 lbs and cost as low as $1,499.00.

Although thermal inkjet systems are compact and lightweight, they offer impressive coding specifications. For example, the Anser U2 Smart can create 400 x 300 DPI codes up to 0.5” tall (1” tall with the Anser U2 SmartOne). Higher-end TIJs like the Anser X1 can create 600 x 600 DPI codes up to 2” tall with stitched printheads.

TIJ printers are often designed for slower speed lines, and intermittent coding tasks including environments with tight production line space, but some models also offer high-speed capabilities. InkJet, Inc. carries numerous TIJ printers of varying specialties and price points. Our current options include:

	The Anser U2 Smart and SmartOne Thermal Inkjet Printer: Compact and cost-effective, the Anser U2 Pro-S is an excellent choice for rigid plastic printing in applications that do not require CIJ-level marking speeds. The Anser U2 Pro-S offers a 76.2 m/min max printing speed, 400 x 300 DPI max resolution, 0.5” max print height, intuitive operation, and easy installation.
	The Anser A1 Thermal Inkjet Printer: The first all-in-one TIJ that offers 2” printing and mid-message DPI adjustments, the Anser A1 is both powerful and affordable. Built with 2 cartridge slots, the A1 can create 2” tall markings with varying DPI elements (e.g., 300 DPI QR code with 150 DPI text). The A1 maxes out at 300 m/min for product marking applications with certain cartridges. Users control the A1 through a large touchscreen interface.
	The Anser X1 Thermal Inkjet Printer: Even though the Anser X1 is a thermal inkjet printer, you wouldn’t know that from its spec sheet. With printing speeds up to 300 m/min, the Anser X1 is one of the most powerful TIJs on the market today. Beyond industrial speed marking, the Anser X1 offers a 600 DPI max resolution, a 2” max print height (with stitched printheads), IP66 protection, and the ability to control two production lines simultaneously.

See the chart below for a closer look into how our TIJ options compare to one another:

InkJet, Inc’s Thermal Inkjet Printer Options
Specification	Anser U2 Pro-S	Anser A1	Anser X1
Max Printheads	1	2	2
Display	3.5” Color LCD with LED backlight	5” Color LCD Capacitive Touchscreen 480 x 800 (portrait)	7” Color LCD Capacitive Touchscreen (800 x 480 px)
Input Device	Pocket-sized IR remote keypad	Touchscreen	Touchscreen
Print Height	0.5”	1” with single printhead, 2” with stitched printheads	1” with single printhead, 2” with stitched printheads
Print Resolution	400 x 300 DPI	300 DPI	600 x 600 DPI
Print Speed	76.2 m/min	121 m/min	300 m/min
Print Distance	0.25” (6mm)	0.25” (6mm)	0.25” (6mm)
Operating Temp.	0°C ~ 40°C (32°F ~ 104°F)	5°C – 40°C (41°F – 104°F)	5°C – 40°C (41°F – 104°F)
IP Rating	N/A	N/A	IP66
Dimensions and Weight	(L/W/H) 4.5” x 3” x 2.4” 0.49kg (1.08 lb) – excluding cartridge and bracket	(L/W/H) 6.7” x 5.4” x 4.9” 1.8kg (3.97lb) w/o guide plate	(L/W/H) 11.5” x 5.6” x 2” 2.7kg (6lb)

High-Quality Inks for Different Packaging Requirements

InkJet, Inc.’s ink line

Flexible packaging substrates range from porous to non-porous, and if you don’t use a formula that you know will work with your specific materials, you run the risk of producing flawed codes. Fortunately, InkJet, Inc. has produced high-quality inks for over 30 years. Our comprehensive catalog contains numerous formulas to meet your needs better.

We offer many formulas with special properties, including:

High-temperature resistance
Alcohol resistance
Sunlight resistance
UV readability
Thermochromic properties
Different color varieties

Simplify Inkjet Printing on Flexible Packaging

Flexible packaging is a great asset to many different industries, but it can be difficult to find the right hardware and ink combination to print with precision and consistency. At InkJet, Inc., we can meet all your printing needs. With a vast portfolio of hardware and ink options, we can ensure that your operation is stocked with the right equipment to mark plastics quickly and legibly. Call us today to learn how we can help improve your operation.

For more information related to inkjet printing on flexible packaging, contact InkJet, Inc. online or by phone at 1(800) 280-3245.

Related Products & Articles

Read Article