Printing on Flexible Packaging

Essential Concerns When Printing on Flexible Packaging

Flexible packaging comes in many different forms and can be made from a variety of materials. Accordingly, there is no “one size fits all” flexible packaging printing solution. For example, if one is placing their products in a pouch primarily made of plastic, printing on the material would require a different printer/ink combination than it would take to print on blister packs covered in aluminum foil. If one doesn’t account for these differences, it can render codes illegible after they’ve been applied. 

With improper codes come a host of issues. Supply chains rely on traceable markings for inventory purposes, shipping information, and quality control. When these codes are unreadable and unscannable, it can cause mass confusion and recalls resulting in expensive consequences for the manufacturer. 

To avoid these costly issues, companies must find a printer/ink combination that can successfully mark their materials with:
 

• Barcodes
• QR codes
• Data matrices
• Expiration dates
• Serial numbers 
• Lot codes
• Batch numbers

This is where InkJet, Inc. can help.

Use the Right Printer for Your Operation

When it comes to printing on flexible packaging, companies can choose from a variety of equipment to complete their coding applications. The best hardware choice will largely depend on the individual needs of an operation. For flexible packaging applications, the most frequently used printer types include: 

• Thermal transfer overprinters (TTO)
• Continuous inkjet printers (CIJ)
• Thermal inkjet printers (TIJ)

For decades, thermal transfer overprinters were often considered the best choice for flexible packaging due to their high-speed capabilities and high-DPI codes—two qualities made possible by TTO’s heating mechanism. By applying heat to thermal ink ribbons, TTO machines are able to create sharp, highly legible codes on products moving at industrial speeds.  However, this same ribbon-heating process can make thermal transfer overprinters more difficult to operate as compared to other marking options. 

For example, when using a TTO machine, operators must account for:

• Periodic ribbon replacements, along with the associated downtime and consumable cost.
• Proper ribbon tension to ensure that codes come out correctly.
• Substantial maintenance costs due to TTO machine complexity and environmental vulnerabilities.

To avoid these concerns, many companies have begun turning to other marking methods for their flexible packaging needs. Most notably, continuous inkjet and thermal inkjet printers offer simpler, more reliable alternatives.  

When using a continuous inkjet (CIJ) printer like the DuraCode Touchscreen, companies don’t have to worry about frequent ribbon replacements or hardware tension. Instead, CIJ printers utilize large bottles of ink and makeup so that they can run for an extended period in an uninterrupted fashion. By using a CIJ printer like the DuraCode to mark flexible packaging, companies benefit from:

• Uninterrupted printing at speeds of 300 meters per minute and above.
• Wide operating temperature range, stretching from 41-113° F (5-45° C).
• Mid-operation fluid and filter changes that reduce maintenance-related downtime.
• Protection against dust particles provided by an IP-rated steel structure. 

As another marking option, thermal inkjet (TIJ) printers offer companies intuitive use, simple setup, and maintenance-free operation. Generally weighing around five pounds, TIJ printers are powered by removable ink cartridges that also operate as printheads. Resulting from this configuration, TIJ printers are easy to move and have fewer maintenance concerns than many other printing options. Furthermore, cutting-edge TIJ printers like the Anser X1 offer levels of environmental resistance and printing speeds that rival many CIJ models. 

Through utilizing the Anser X1 TIJ printer to mark flexible packaging, companies benefit from:

• High-speed printing, maxing out at 300 meters per minute.
• Great code resolution, reaching 600 DPI.
• Wide operating temperature range, stretching from 32-104° F (0-40° C).
• Total dust ingress protection enabled by the IP66-graded housing.
• Large-image coding possible of reaching a 2-inch print height when stitching printheads.

Find the Best Ink for Your Materials

Regardless of whether you’re using a thermal transfer overprinter, a continuous inkjet printer, or a thermal inkjet printer, you won't be able to successfully mark your materials if you don’t use the right ink. 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. offers a diverse ink portfolio that is filled with unique formulas that are compatible with any number of flexible packaging materials. 

At InkJet, Inc, we have been developing formulas for over 30 years. From this experience, we have obtained the knowledge necessary to provide companies with the best formulas to fit their needs. Further, if you have specific substrate requirements that go beyond what standard formulas can deliver, we offer custom ink services to meet every specification.  These custom offerings can include:

• High-temperature resistance
• Alcohol resistance 
• UV readability
• Thermochromic properties (i.e., color changes after the retort cycle)
• Different color varieties