Inkjet Coding and Marking Comparisons: Today's Top Solutions

Laser, Continuous Inkjet, and Thermal Inkjet Coding and Marking Speed

When looking for a laser or inkjet coding and marking solution, speed is one of the first qualities to consider. Product coding needs differ widely from one operation to the next. While one company may need to print more than 1,000 codes per minute, another might only need to print 10 per minute.

For high speed lines, continuous inkjet printers and laser systems are ideal options. Both CIJ printers and laser systems are capable of uninterrupted coding up to 24 hours a day. CIJ printers like the DuraCode Touchscreen have a max speed of 320 m/min, which is well-suited for high-volume marking applications, such as:

• Beverage bottling lines
• Food packaging
• Wire and cable extrusion

Laser systems offer similar marking speeds—up to 2,000 characters/second—making them another solid option for high-speed lines. Laser systems also offer the unique ability to mark stationary materials. CIJ and TIJ printers can only print on moving materials. The ability to mark still products is a great advantage for metal shop workers and aerospace/automotive part designers who don’t have the space or need for a conveyor-powered production line.

If you don’t require the industrial strength of CIJ or laser systems, however, a TIJ printer will be a better fit for you. Although TIJ and CIJ printers have similar titles, they operate very differently. In general, most entry thermal inkjet printer model speeds are substantially lower than continuous inkjet printer speeds.

A standard TIJ such as the Anser U2 Smart maxes out at 76.2 m/min, which is better suited for smaller-scale operations. However, newer TIJ models offer speeds that challenge this generalization such as the Anser A1 and X1 printers. The Anser X1, for example, can mark products moving at 300m/min, rivaling CIJ speeds.

Laser systems have longer throw distances than both CIJ and TIJ printers. Depending on the laser model, throw distance ranges from one inch to five or more inches. To produce a clear code, however, you must adjust the machine’s focal length until it reaches the ideal distance from the substrate.

Focal length measures the distance from the scanning head to the light’s focal point (i.e., the end of the beam that contacts the substrate). Operators must set the focal length to an appropriate distance to create a clear image. If the head is too close to the substrate, it can burn the product; if the head is too far, it won’t create the intended marking.

Thankfully, it is easy to set the ideal focal length with today’s technology. In the past, operators would have to take physical measurements themselves when adjusting focal length. Now, all of InkJet, Inc.’s laser models come with auto-focusing features that allow operators to make quick adjustments and avoid downtime when switching between products.

Compared to CIJ printers, TIJ systems are better suited for creating larger, higher-quality codes. TIJ models like the Anser U2 SmartOne offer print heights up to one inch and can create higher-quality images than CIJ printers. Some TIJ models like the innovative Anser A1 and top selling Anser X1 can stitch multiple printheads together as well, enabling print heights up to two inches.

These size capabilities make TIJ printers valuable case coding technologies. However, be aware that stitched printheads require close care to create clean, blank-space-free markings. If you need to regularly create markings that are larger than two inches, a high-resolution case coder is likely a better fit for you.

Laser systems are another good choice for large prints. Fiber laser systems can have print windows as large as 300mm x 300mm, while CO2 laser print windows can reach 400mm x 400mm. These large windows open the possibility for diverse coding applications, including:

• Large images
• Machine-scannable codes
• Multi-product coding 

For example, if your work environment is prone to dust and water, look at the different IP ratings of your marking system options. Most CIJ printers are built with protected cabinets rated at around IP55. IP55 ratings mean that the unit is:

1. Significantly protected against dust ingress.
2. Fortified against low-pressure jets of water from all angles.

Comparatively, most TIJ models are built with little or no ingress protection. This lack of protection makes TIJ printers susceptible to water damage and dust issues, especially in the ink cartridge itself. Newer, more advanced TIJ models prevent this problem in different ways. For instance, the Anser X1 is built with an IP66 housing that protects the unit from water and dust issues.

Laser systems typically offer similar protections as CIJ printers and will usually have IP ratings at least as high as IP54. Specialty models will reach IP65 as well.

For more information on printing in harsh environments, read our blog on protecting coding and marking resources.

The wide ink compatibility and long throw distance of CIJ printers makes them ideal for applications like wire extrusion coding and food can printing that require specialty formulas.

TIJ printers do not offer this same level of material diversity because they are not compatible with as many inks. Many TIJ printers are designed to only print on either porous or non-porous materials. Even the TIJ printers that are compatible with porous and non-porous inks do not have access to the specialty inks used by CIJ printers.

For laser systems, material compatibility is defined by wavelength. CO2, fiber, UV, and LDR systems produce beams at different wavelengths, which impacts whether one laser type can successfully mark a certain material or not.

Laser systems must also be installed by a trained technician, not only to ensure proper operation but also to guarantee the safety of the facility’s workers. During operation, laser systems release potentially harmful fumes into the environment. Laser beams themselves are dangerous as well, as they can burn skin upon contact.

To comply with safety regulations, any laser-equipped facility must have:

1. Fume extractors installed on the line to prevent harmful materials from entering the air.
2. Beam shields installed to protect workers from injury.

Following installation, laser system use becomes much easier thanks to built-in software guides and programs that show workers how to use the system.

Like TIJ printers, laser systems have few maintenance requirements. As long as you are cleaning the basic components of your system, you should not need professional help. You will need to replace the system’s tubes and filters on an ongoing basis, however. These expenses are much smaller than the ink refills required by CIJ and TIJ printers.

Integration Possibilities

Larger operations running 24/7 will want  the printer integration with their PLC and further integration into information systems at their production lines—they’ll want to integrate their printers into their information systems.

Laser systems have the most integration possibilities and can communicate with UDP, TCP/IP, Serial/RS232, and remote internet systems. Innovative TIJ systems such as the Anser A1 have advanced I/O capabilities designed for quick data integration with ERP systems such as SAP. TIJ and CIJ printers have fewer capabilities but can be integrated into PLC systems.