Carton Printing & Packaging: Challenges and Solutions | InkJet, Inc.

Carton Printing & Packaging: 10 Challenges and Solutions

Issue

Challenge

Solution

1) Ink Adhesion

➖ Porous carton surfaces make it challenging for inks to adhere properly.

➕ Use inks formulated explicitly for carton materials or pre-treatment processes to improve ink adhesion.

2) Color Consistency

➖ Color consistency can be tricky between batches or print runs.

➕ Set up a color management system, use standardized color profiles, and calibrate printers to ensure color consistency.

3) Bleeding and Smudging

➖ Smudging or bleeding can happen if the carton material absorbs ink.

➕ Use quick-drying inks and integrate proper drying mechanisms into the printing process.

4) Die Cutting Precision

➖ Die-cutting carton packaging can be tricky, leading to misalignment or irregular shapes.

➕ Invest in high-precision die-cutting equipment and conduct testing to ensure accurate alignment and shape conformity.

5) Folding and Creasing Issues

➖ Folding and creasing cartons can cause cracking or distortion of printed elements.

➕ Choose flexible carton materials and adjust printing settings to minimize stress on the printed areas during folding and creasing.

6) Printing on Irregular Surfaces

➖ The surface of carton packaging can be uneven or textured, making printing challenging.

➕ Use printing methods for uneven surfaces, such as flexography, and adjust parameters to accommodate surface variations.

7) Moisture and Humidity

➖ Moisture and humidity can affect the quality of printing on carton packaging.

➕ Maintain optimal humidity levels in the printing area and store carton materials in a controlled environment before printing.

8) Regulatory Compliance

➖ Regulatory requirements for barcodes, safety symbols, and legal text can be challenging to meet.

➕ Plan the design layout to meet regulations, conduct regular reviews to ensure compliance, and consult with regulatory experts.

9) Cost Constraints

➖ Budget limitations can impact the choice of printing methods and materials.

➕ Optimize printing processes for efficiency, use cost-effective printing methods, and negotiate bulk discounts.

10) Prototyping

➖ Creating accurate prototypes for testing can be time-consuming and costly.

➕ Use digital prototyping tools and work with printing providers to reduce prototyping time and cost.

InkJet, Inc.’s Carton Printing Systems

Coding Technology

Operating Method

System Options

Maximum Resolution and Print Height

Maximum Marking Speed

Cost Factors

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

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

Anser X1

600 x 600 DPI at 1” height (2” height with stitched print heights)

300 m/min

Moderate unit cost, moderate consumable cost

Hi-Res Case Coder

Propels oil-based ink droplets to create stark codes

Precision Series 18mm & 72mm

180 DPI at 18 mm height or 72 mm height

Low to moderate speed

Moderate unit cost, low consumable cost