Method and device for efficiently printing a decoration on a substrate material

Abstract

The invention relates to a method and a device for efficiently printing a design onto a substrate. According to the invention, the amount of primer applied to a substrate is adapted to the design to be printed.

Description

[0001] The invention relates to a method and a device for efficiently printing a design onto a substrate. According to the invention, the amount of primer applied to a substrate is adapted to the design to be printed.

[0002] Decorative substrates, such as wood-based panels, are typically used as flooring or for cladding walls and ceilings. In the past, these substrates were usually coated with decorative paper, and the variety of patterned decorative papers was virtually limitless. As an alternative to using decorative papers, direct printing onto substrates has emerged, eliminating the need for printing on paper and then laminating or directly coating the substrate.

[0003] The main printing techniques used here are gravure printing and digital printing. Gravure printing is a technique in which the elements to be printed are recesses in a printing plate, which is inked before printing. The ink is primarily located in the recesses and is transferred to the substrate, such as a substrate, due to the pressure of the printing plate and adhesive forces. In digital printing, on the other hand, the image is transferred directly from a computer to a printing machine, such as a laser printer or inkjet printer. This eliminates the need for a static printing plate.

[0004] Digital printing, for example, uses the CMYK or CMRK color system. The CMYK color model is a subtractive color model, where the abbreviation CMYK stands for the three color components cyan, magenta, yellow, and the black component (key) as the color depth. In the CMRK color system, red is used instead of magenta. These color systems allow for the representation of a color space (gamut) that meets many requirements from a wide variety of fields.

[0005] Color variations in the substrate materials affect the printing result and thus directly impact print quality. Therefore, substrate materials are primed to create a uniform printing surface. Application rates of 30 g / m² to 80 g / m² are not uncommon.

[0006] It is known from the prior art that the whiteness, color, or brightness of the primer layer is monitored using suitable measuring technology in order to intervene if deviations from specified target values ​​occur. This ensures that uniform whiteness levels are used for all decors from a decorboard manufacturer, thus achieving consistent printing results. EP 2 860 037 A1, for example, addresses this issue. In this way, consistent printing results can be achieved. The material costs for applying the primer layers therefore represent a significant cost factor in known printing processes.

[0007] The digital decor data sets, which contain the color values ​​for printing the respective decors, are aligned with the uniform printing base thus created. Regardless of the printing process used (digital printing or gravure printing), the printing inks used and their quantities represent a crucial cost factor.

[0008] The costs for printing inks and primers are constantly rising, so saving on these materials while maintaining good print quality is desirable and would directly increase the cost-effectiveness of decorative printing.

[0009] Based on the prior art, the invention therefore aims to make the printing of a decoration onto a substrate more cost-efficient and, in particular, to save printing ink and / or primer.

[0010] The invention solves this problem by means of a method according to claim 1 and a device according to claim 11. Detailed description

[0011] The invention provides a method for efficiently printing a design onto a substrate. Any imaginative design or designs that mimic natural materials can serve as the design. Popular examples include wood designs, stone designs, and tile imitations.

[0012] According to the invention, a decoration is provided in the form of a digital file. A digital decoration data set is created and stored from the digital file, which includes the color values ​​for printing the decoration.

[0013] According to the invention, a carrier material is further provided. Preferably, the carrier material is plate-shaped.

[0014] In principle, any type of sheet-shaped substrate material can be used that is known to the specialist in connection with decorative printing in the field of floor covering elements and cladding of walls and ceilings.

[0015] In one embodiment, the substrate material is selected from the group comprising paper, glass, metal, foils, wood-based materials, in particular MDF, HDF and CDF boards, veneers, lacquer coatings, plastic boards, KIWI boards and inorganic substrate boards, such as cement particleboard, cement fiberboard and gypsum fiberboard.

[0016] KIWI boards consist of a mixture of wood-based material, paper, and binders, and are PVC-free. For example, these boards are made up of approximately 80% wood and approximately 20% paper and binders.

[0017] Furthermore, a primer is provided. According to the invention, the primer is a pigmented primer, meaning it contains pigments of a color, particularly preferably pigments of a light color, and particularly preferably at least one white pigment.

[0018] White pigments are achromatic inorganic pigments with a high refractive index (greater than 1.8), primarily used to produce optical whiteness in paints or as fillers in, for example, plastics. White pigments according to the invention can be selected from the group consisting of titanium dioxide, lithopone, barium sulfate, zinc oxide, zinc sulfide, and calcium sulfate. Lithopone is a white pigment containing barium sulfate and zinc sulfide.

[0019] The process according to the invention is particularly environmentally friendly, since no compounds containing toxic heavy metals are used as white pigments.

[0020] In a preferred embodiment, titanium dioxide is used as a white pigment in the water-based pigmented primer, since titanium dioxide has the highest refractive index and thus the highest opacity among the known white pigments.

[0021] A pigment-containing aqueous resin solution and / or a pigment-containing radiation-curable filler can be applied as a primer to the side of the substrate to be printed. Suitable primers include aqueous resin solutions such as melamine-formaldehyde resin, urea-formaldehyde resin, or melamine-urea-formaldehyde resin, all containing pigments. It is also possible to pre-coat or prime the substrate with a 1K / 2K acrylate, UV-cured, and / or ESH filler containing at least one pigment.

[0022] In a preferred embodiment, the primer comprises an aqueous resin solution, in particular an aqueous solution of a melamine-formaldehyde resin, a urea-formaldehyde resin, or a melamine-urea-formaldehyde resin. The liquid resin may additionally comprise suitable wetting agents, hardeners, release agents, and defoamers.

[0023] In another embodiment of the present method, the substrate material can be primed with a 1K / 2K acrylate and / or ESH filler containing at least one pigment. A UV-curable filler advantageously consists essentially of UV-curable coating components, pigments, reactive diluents, and radical initiators as chain starters.

[0024] According to the invention, n Predefined decor groups, with n ∈ N Each of the n Each decor group comprises a different application quantity of primer, with the degree of whiteness of the primed substrate being known for each decor group. This means that the degree of whiteness of the selected substrate when primed with a defined application quantity of the specified primer is known.

[0025] The degree of whiteness is a measure of a surface's reflectivity. It thus provides an objective quantity for determining the difference between two light-colored surfaces. By definition, a higher numerical value represents a "whiter" white.

[0026] The degree of whiteness can be determined using various methods known to experts. It is important to note that only degrees of whiteness determined using the same method can be compared. Among other methods, the L* value of the L*ab color space can also be used to determine the degree of whiteness.

[0027] For measuring whiteness in decorative printing, devices from companies like Hunterlab are well-known. The L* value is measured using colorimeters such as those offered by ipac and AVT.

[0028] For each substrate material, the degree of whiteness achieved with a specific application quantity of primer is known. According to the invention, for a defined substrate material and a defined primer, decorative groups are specified, to which defined application quantities of primer and the corresponding degree of whiteness are assigned.

[0029] In principle, the less primer is applied, the more the color of the substrate shows through and the lower the whiteness of the primed substrate.

[0030] In one embodiment of the present method, 2 to 10, preferably 2 to 8, particularly preferably 2 to 6 decorative groups are specified.

[0031] For example, if 3 decor groups are specified, they can have the following exemplary properties: Decor group Application quantity primer Whiteness determined by L* value 1 30 g / m²< 92,0 (+ / - 1,0) 2 25 g / m²< 90,0 (+ / - 1,0) 3 20 g / m²< 88,0 (+ / - 1,0)

[0032] Decor group 1 corresponds to the conditions of a conventional printing process. In decor group 1, a whiteness level of L* = 92.0 is achieved. This is necessary to print very light decors in good quality. In decor groups 2 and 3, the amount of primer applied is reduced, which decreases the whiteness level.

[0033] According to the invention, the color values ​​in the digital decor data set are adapted to each decor group using the degree of whiteness. This means that the color values ​​are adjusted so that the decor can be printed on the primed substrate with unchanged quality using the adapted color values. This is limited by the fact that, in particular, very light decors can no longer be printed with sufficient quality due to the substrate color showing through.

[0034] The color values ​​are adjusted using a suitable computer program. This program is also able to determine whether or not the design can be printed with the same quality. Suitable computer programs are known to those skilled in the art. These could include, for example, Adobe Photoshop or Colorgate. The adjusted color values ​​are stored in a specific embodiment.

[0035] According to the invention, the decoration is further assigned to the decoration group that has the smallest application amount of primer and enables reproduction of the decoration in print with a quality equivalent to that achieved in a printing process where the whiteness of the primed substrate is L* = 92.0 (±1.0). According to the invention, this assignment is carried out by the computer program, which also adjusts the color values. In a preferred embodiment, this assignment is stored for the decoration, the substrate, and the respective primer.

[0036] In this context, the quality of the print means that no color deviation is perceptible to the naked eye between printed substrates produced using the following printing processes (1) and (2): (1) The substrate is primed with an amount sufficient to achieve a whiteness level of L* = 92.0 (+ / - 1.0), followed by printing of the design with optimal color values. (2) The substrate is primed with a reduced amount of primer according to the design group, followed by printing of the design with color values ​​adapted for that design group.

[0037] In both cases, the same substrate materials, primers, printing devices, and printing inks are used. However, according to the invention, color deviations that are perceived by humans as significant or strong are unacceptable.

[0038] In one embodiment, the print quality can be assessed by visual evaluation by a person skilled in the art and / or by color measurement. Color measurement is preferably performed using a hyperspectral scanner, for example, an ACMS system from IPAC. If color measurements are performed, the agreement of the color values ​​of the printing processes (1) and (2) described above should be between 90 and 100%, preferably between 95 and 100%, to ensure sufficiently high quality.

[0039] Surprisingly, it has been shown that the amount of ink used for printing can be reduced using the method according to the invention. With conventional primer application, a high ink application is necessary to cover the "white" background in dark designs. Due to the reduced whiteness of the primed substrate material according to the invention, the ink application can advantageously be reduced in dark designs, since the translucent color of the substrate material enhances the visual appearance of the printed design. Furthermore, the smaller amount of primer applied also saves material.

[0040] Reducing the amount of ink and primer applied leads to significant savings in material costs, thus increasing the efficiency of the printing process according to the invention. Additionally, drying times in the printing systems can be reduced because the application quantities of primer and printing ink are lower, and the correspondingly thinner layers can dry more quickly. This also increases the efficiency of the printing process according to the invention, as energy costs can be saved and the printing process accelerated.

[0041] According to the invention, the application rate of a specific primer to a specific substrate is optimized depending on the design. With suitable designs, the color of the substrate advantageously enhances the appearance of the printed design by showing through the primer. The smaller the application rate of the primer, the more the color of the substrate shows through. The darker the design to be printed, the more pronounced this effect can be.

[0042] According to the invention, the primer is applied to the provided substrate material in an application quantity corresponding to the decor group specified for the decor. According to the invention, the primed substrate material is then dried.

[0043] In one embodiment, the primer is applied in 1 to 10, preferably 1 to 5, and particularly preferably 1 to 3 layers. If several layers of primer are applied, in one embodiment each layer is dried after application.

[0044] According to the invention, the drying of the primer layers can be carried out using a convection dryer or a near-infrared dryer. Of course, any other dryer known and suitable to those skilled in the art can also be used.

[0045] In one embodiment, the present method further comprises the following steps: After the primer has been applied and dried on the substrate, the whiteness of the primed substrate is measured; an average is calculated from the whiteness measurements and compared with the whiteness specified for this decor group; the digital decor data set is adjusted to the measured whiteness and / or another primer is applied to the substrate if the average of the measured whiteness does not match the whiteness specified for the decor group.

[0046] These process steps allow the whiteness of the primed substrate to be checked during the production process. Due to variations in the quality and thus the color of the substrate and / or a faulty application of the primer, the whiteness of the primed substrate may deviate from the whiteness specified and therefore expected for this decor group. To prevent defective printing results as a result, this embodiment includes a whiteness check. If deviations in whiteness are detected, the digital decor data set can be adjusted to the measured whiteness and / or an additional primer layer can be applied to the substrate. This prevents poor-quality decor prints.

[0047] Checking the whiteness of the primed substrate is already a standard procedure in many production facilities. Therefore, existing plant structures can be used to their advantage.

[0048] According to the invention, the primed substrate material is printed with the decoration using the digital decoration data set adapted for the decoration group.

[0049] The substrate can be printed using a direct or indirect printing process. In particular, gravure printing and digital printing processes can be used. In a particularly preferred embodiment, a digital printing process is employed.

[0050] In one embodiment, the printed design is dried after the printing ink has been applied. Convection dryers or near-infrared dryers can be used for this purpose.

[0051] In one embodiment, the resulting layer structure is pressed under pressure and temperature to form a laminate. A short-cycle press is preferably used for this purpose.

[0052] In one embodiment, at least one protective layer is applied after the printed substrate material has dried.

[0053] In one embodiment, a protective layer can be applied directly to the decorative print, consisting of either a resin (preferably a water-compatible resin), a radiation-curable, typically non-water-compatible varnish (e.g., selected from the group of acrylates, modified acrylates, and / or epoxies), or polyurethanes with good adhesion properties. After the protective layer has partially cured or gelled, the printed panels can be temporarily stored without risk of surface damage or contamination of the decorative layer. Thus, even with undefined time intervals between a decorative printing step and a subsequent processing step, no problems such as panel contamination, abrasion, and / or detachment of the decorative layer are to be expected. This also ensures that the printing device does not have to stop operating during a downstream processing interruption.

[0054] In one embodiment, the protective layer to be applied to the decorative layer of the substrate material comprises at least one water-compatible resin, preferably a formaldehyde-containing resin, in particular preferably melamine-formaldehyde resin, urea-formaldehyde resin and / or melamine-urea-formaldehyde resin. The resin can therefore be applied in liquid or solid form, with the use of a liquid resin being preferred.

[0055] Subsequently, the protective layer, comprising at least one water-compatible resin, is pre-dried until the resin is still flowable and cross-linkable. This pre-drying of the water-compatible resin-containing protective layer typically takes place in a continuous drying oven, such as those used in the production of wood-based panels. Depending on the application quantity, the pre-drying process can take 5 to 15 seconds, preferably 5 to 10 seconds.

[0056] If a radiation-curable coating is used as a protective layer, the subsequent gelation of the protective layer can be carried out using UV radiation (e.g., at 320-400 nm), ESH radiation, and / or NIR radiation. After gelation, the coating preferably has a degree of polymerization between 20 and 60%, more preferably 30-50%.

[0057] In a further variant of the present method, the protective layer to be applied to the printed side of the carrier material is applied in an amount between 5 and 50 g / m², preferably 8 and 30 g / m², and particularly preferably 10 and 20 g / m².

[0058] It is also possible to apply at least one protective layer to the decor, in particular a layer comprising abrasion-resistant particles, natural fibers, synthetic fibers and / or other additives, whereby resins such as melamine-formaldehyde resin, or urea-formaldehyde resin, acrylate resins and polyurethane resins can be used as suitable binders.

[0059] In a further embodiment of the method according to the invention, several protective layers are applied to the decoration, which may include different additives.

[0060] In a preferred embodiment, the method according to the invention therefore comprises the following steps: Applying a first resin layer containing abrasion-resistant particles to the decorative side of the substrate, drying the first resin layer to a residual moisture content of 3% to 6%; and / or applying a resin layer containing fibers to the decorative side of the substrate, drying the second resin layer to a residual moisture content of 3% to 6%; and / or applying at least a third resin layer containing glass particles to the decorative side of the substrate, drying the third resin layer to a residual moisture content of 3% to 6%; and pressing the layer structure under pressure and temperature to form a laminate.

[0061] The abrasion-resistant particles are preferably selected from the group containing aluminum oxides, corundum, boron carbides, silicon dioxides, silicon carbides, and glass particles. Natural and / or synthetic fibers are particularly those selected from the group containing wood fibers, cellulose fibers, wool fibers, hemp fibers, and organic or inorganic polymer fibers.

[0062] Conductive substances, flame retardants, luminescent materials, and metals can be added as additives. The conductive substances can be selected from the group containing carbon black, carbon fibers, metal powders, and nanoparticles, particularly carbon nanotubes. Combinations of these substances can also be used. Phosphates, borates, especially ammonium polyphosphate, tris(tribromopentyl)phosphate, zinc borate, or boric acid complexes of polyhydric alcohols are preferred as flame retardants. Fluorescent and / or phosphorescent substances of inorganic or organic origin, especially zinc sulfide and alkaline earth aluminates, are preferred as luminescent materials.

[0063] Preferably, corundum particles are included in the first resin layer to increase abrasion resistance. This is particularly important when used as flooring panels to withstand the high loads to which they are subjected. For example, a mixture of common silanized corundums of varying grain sizes is used. The corundum can simply be added to the resin before application.

[0064] Cellulose fibers are preferably used as fibers in the second resin layer. Commercially available fibers can be used for this purpose and can also be added to the resin layers to be applied.

[0065] The glass particles contained in the third resin layer are, for example, commercially available micro glass beads. These can also be easily incorporated into the resin layer to be applied.

[0066] The third resin layer contains 20% glass particles. Approximately 5% cellulose has proven advantageous for the second resin layer. The first resin layer contains, in particular, 20% corundum particles.

[0067] In a further embodiment of the method according to the invention, several resin layers can also be applied to the underside of the substrate material. This particularly compensates for the tensile forces acting on the top side of the substrate material due to the resin layers applied to the top side. In a particularly preferred embodiment, the resin layers applied to the top and bottom sides are applied in equal quantities, or the counter-tension applied to the underside of the substrate material corresponds exactly in layer structure and layer thickness to the layer sequence applied to the top side.

[0068] The resin layers applied to the underside of the substrate material may be colored.

[0069] Additives such as hardeners, wetting agents and release agents can be added to all resin layers.

[0070] The resin layers on the top and bottom of the substrate material can contain a 60% synthetic resin solution.

[0071] Drying to a residual moisture content of 3% to 6% serves to prevent the cross-linking process of the applied resin layers.

[0072] In a further embodiment of the present method, the printed substrate, optionally provided with one or more protective layers, is further processed or finished in a short-cycle press. Under the influence of pressure and temperature in a short-cycle press, the resin layers remelt. This continues the crosslinking process. The individual resin layers are thus crosslinked not only within themselves but also with each other. As a result, the applied melamine resin layers, including the decorative layer, can be crosslinked and cured to form a laminate. Typical short-cycle presses operate, for example, at a pressure of 30 to 60 kg / cm², a surface temperature of the substrate of approximately 165 °C, and a pressing time of 6 to 12 seconds.

[0073] During further processing in the short-cycle press, surface structures can also be created on at least one surface, preferably at least the top surface of the substrate material, using a structured press plate. These structures can optionally be designed to match the decor (so-called decor-synchronous structure). Preferably, the surface structures are largely congruent with the decor. In this case, they are referred to as embossed-in-register structures. For wood decors, the structures can be in the form of a pore structure that follows the grain. For tile decors, the structures can be indentations in the area of ​​the grout lines encompassed by the decor.

[0074] Furthermore, the invention provides a device for efficiently printing a decoration onto a substrate material. a computing unit; at least one device for applying a primer to a substrate; at least one printing device; at least one drying device; available.

[0075] All features described for the method according to the invention apply equally to the device according to the invention and vice versa.

[0076] In a preferred embodiment, the device according to the invention is configured to carry out the method according to the invention.

[0077] According to the invention, the device includes a computing unit configured to perform process steps a to e. The computing unit can be a PC, laptop, or similar device equipped with suitable software. Suitable software is known to those skilled in the art and can, for example, be Adobe Photoshop or Colorgate.

[0078] The device for applying a primer to a substrate can be, for example, a roller mill or a device that sprays the primer onto the substrate.

[0079] The at least one printing device can be a device that performs direct or indirect printing. Preferably, the printing device is a digital printer or a device for gravure printing. A digital printer is particularly preferred.

[0080] Furthermore, the device according to the invention comprises at least one drying device. This device is used to dry the primer and / or the printing ink after application to the substrate. For this purpose, a convection dryer or a near-infrared dryer can be used, for example. In principle, any dryer known to those skilled in the art and suitable for drying primer layers and / or the printing ink on the substrate can be used.

[0081] In a further embodiment, the device according to the invention also includes a device for measuring the whiteness of a substrate material. Suitable devices are known to those skilled in the art. In addition to commercially available whiteness measuring devices, any device capable of determining the L* value of the substrate material can be used. The L* value can be determined, for example, using a conventional colorimeter, preferably an online colorimeter. The evaluation of the measured color values ​​and the determination of the average value can be performed on the at least one processing unit of the device. The processing unit includes suitable software for this purpose. Suitable software has already been mentioned.

[0082] In one embodiment, the device further comprises an application unit for applying at least one protective layer. Suitable application units are known to those skilled in the art and apply the protective layer, for example, by spraying or rolling.

[0083] In a further embodiment, the device also includes a device for pressing a layered structure under pressure and temperature to form a laminate. According to the invention, the layered structure comprises at least the substrate material, the primer, and the printed decoration. The layered structure may also include a protective layer. In a preferred embodiment, this is a short-cycle press.

[0084] The present invention thus provides a very efficient and cost-saving printing process. The advantages are summarized below: The present invention enables savings in material costs, particularly for medium and darker designs, by using an adapted application quantity of primer to the decorations to be printed. These savings result from reductions in both the amount of primer and the amount of printing ink required. Energy costs for drying the primer and printing ink are also reduced because the application quantities are smaller, thus shortening drying times.

[0085] The invention will be explained in more detail below using 7 exemplary embodiments. Example 1 - Digital print dark decor walnut

[0086] A walnut decor was to be developed and produced for a new flooring collection. The decor was to be digitally printed at a wood-based panel manufacturer onto HDF core boards measuring 207 x 280 cm using the colors cyan, red, yellow, and black. The walnut decor was provided as a digital file. A digital decor data set was created from this file, containing the color values ​​for printing the decor on the digital printing system. A primer was also provided, and the following three decor groups were specified, with decor group 1 corresponding to the conditions of a conventional printing process. Decor group Application quantity primer Whiteness determined by L* value 1 30 g / m²< 92,0 (+ / - 1,0) 2 25 g / m²< 90,0 (+ / - 1,0) 3 20 g / m²< 88,0 (+ / - 1,0)

[0087] The color values ​​in the digital decor dataset were adjusted to each decor group using the known degree of whiteness. The decor could then be assigned to decor group 3.

[0088] The primer was applied to the substrate using three coats. After each coat, the primer was allowed to dry. This resulted in a total primer application rate of 20 g / m². The decorative element was then printed onto the primed substrate. This required an ink application rate of 6.4 g / m².

[0089] For comparison, the same decor was applied to the same type of substrate using a conventional printing process with the same digital printer. The substrate was primed before printing, with the primer applied at the conventionally used rate of 30 g / m². Due to the very dark colors in the walnut decor to be printed, a higher ink rate of 10.6 g / m² was required in this printing process to cover the light background of the primer.

[0090] In this case, the inventive method resulted in a 30% reduction in material costs for both the primer and the printing ink. Furthermore, the smaller order quantities reduced the energy consumption of both the primer drying device and the printing ink drying device by approximately 30%. The inventive method thus offers a significant economic advantage over prior art methods. Example 2 - Digital print dark decor walnut

[0091] Exemplary embodiment 2 essentially corresponds to exemplary embodiment 1, but additionally includes a check of the degree of whiteness of the primed substrate material.

[0092] After the final primer layer had dried, the whiteness of the primed substrate was measured at three positions across the print width and at ten positions along its length using a monitoring device. An average whiteness value for the primed layer was then calculated using suitable software. The measured whiteness corresponded to the expected whiteness for this decor group, thus requiring no corrective action. The primed substrate was then printed with the decor. Example 3 - Digital print medium decor natural oak

[0093] Exemplary embodiment 3 essentially corresponds to exemplary embodiment 1. The decoration was assigned to decoration group 2; consequently, the primer was applied to the substrate at a rate of 20 g / m². An ink application rate of 4.3 g / m² was required for printing the decoration.

[0094] For comparison, the same design was applied to the same type of substrate using a conventional printing process with the same digital printer. The substrate was primed before printing, with the primer applied at the conventionally typical rate of 30 g / m². Printing the design required an ink application rate of 11.1 g / m². In this case, approximately 15% of the material costs for both the primer and the printing ink were saved. Example 4 - Analog printing, dark cherry decor

[0095] This embodiment also corresponds essentially to embodiment 1, except that a roller printing process was used instead of digital printing. Four rollers were used for printing. Ink consumption was measured by weight. The decoration was assigned to decoration group 3 according to the inventive method; consequently, the substrate was primed with a coating of 20 g / m². A coating of 8.4 g / m² was required for printing the decoration.

[0096] For comparison, printing was also carried out on a substrate primed according to decoration group 1. This print required an ink application rate of 11.1 g / m². The inventive method advantageously resulted in a 30% reduction in material costs for both the primer and the printing ink. Example 5 - rearranged decor group

[0097] The process was based on a known decor that is already printed using conventional methods and sold as a product. The digital file of the decor was fed into the inventive process. The decor could be assigned to decor group 2, which allowed the primer application rate to be reduced from 30 g / m²< to 25 g / m²< and the ink application rate from 4.8 g / m²< to 4.1 g / m²<. This resulted in savings of approximately 15% in both ink application rate and primer application rate. Example 6 - colored carrier plate Kiwi

[0098] Exemplary embodiment 6 is essentially the same as exemplary embodiment 1. However, the substrate material used is a colored board composed of wood-based material, paper, and a binder. This board is sold commercially under the name "Kiwi".

[0099] The substrate had a gray base color. A concrete-effect decor was to be printed onto the substrate. Based on the substrate's base color, in combination with the provided primer, the decor could be classified as belonging to decor group 3. Therefore, a primer was applied to the substrate at a rate of 20 g / m². An ink application of 3.7 g / m² was required for printing the decor.

[0100] The same design was also to be printed onto a substrate with a brown base color. In this case, the design was assigned to design group 1. A primer with a density of 30 g / m² was required, and an ink coating of 5.5 g / m² was necessary for printing the design.

[0101] Therefore, by using the grey carrier plate, 30% of the primer and 50% of the printing ink consumption could be saved. Example 7 - Digital print dark decor walnut

[0102] Exemplary embodiment 7 essentially corresponds to exemplary embodiment 2 and therefore included a check of the degree of whiteness of the primed substrate material.

[0103] After the final primer coat had dried, the whiteness of the primed substrate was measured at three positions across the print width and at ten positions along its length using a monitoring device. An average whiteness value for the primed layer was calculated using suitable software. The measured whiteness was below the expected whiteness for the decorative group. As a corrective measure, another primer coat was applied. Upon remeasurement, the whiteness of the primed substrate now corresponded to the whiteness intended for the decorative group. The primed substrate was then printed with the decorative design.

Claims

1. Method for efficiently printing a decoration onto a substrate characterized by the fact that The procedure comprises the following steps: a. providing a decor in the form of a digital file and creating a digital decor data set including the color values ​​for printing the decor; b. providing a substrate material; c. providing a primer; d. specifying n Decorative groups that include different application quantities of primer, with n ∈ N, wherein the degree of whiteness of the primed substrate is known for each decor group; e. Adapting the color values ​​in the digital decor data set to each decor group using the degree of whiteness; and assigning the decor to the decor group that has the lowest primer application rate and allows the decor to be reproduced in print with a quality equivalent to that achieved in a printing process where the degree of whiteness of the primed substrate is L* = 92.0 (±1.0); f. Applying the primer to the substrate with an application rate corresponding to the decor group specified for the decor; g. Drying the primed substrate; h. Printing the decor onto the primed substrate using the digital decor data set adapted for the decor group; 2. Method according to claim 1, characterized by the fact that 2 to 10, preferably 2 to 8, particularly preferably 2 to 6 decorative groups are specified.

3. Method according to any of the preceding claims, characterized by the fact that • After the primer has been applied to and dried on the substrate, the whiteness of the primed substrate is measured; • an average is calculated from the whiteness measurements and compared with the whiteness specified for this decor group; • the digital decor data set is adjusted to the measured whiteness and / or another primer is applied to the substrate if the average of the measured whiteness does not match the whiteness specified for the decor group.

4. Method according to any of the preceding claims, characterized by the fact that The primer is selected from the group comprising pigment-containing aqueous resin solution and a pigment-containing radiation-curable filler and combinations thereof.

5. Method according to any of the preceding claims, characterized by the fact thatThe primer is applied in 1 to 10, preferably 1 to 5, particularly preferably in 1 to 3 layers.

6. Method according to any of the preceding claims, characterized by the fact that After the printed substrate has dried, at least one protective layer is applied.

7. Method according to claim 6, characterized by the fact that the at least one protective layer comprises at least one water-compatible resin, preferably a formaldehyde-containing resin, in particular preferably melamine-formaldehyde resin, urea-formaldehyde resin and / or melamine-urea-formaldehyde resin.

8. Method according to claim 6, characterized by the fact thatcomprising at least one protective layer comprising at least one radiation-curable lacquer selected from the group of acrylates, modified acrylates and / or epoxides, or at least one polyurethane selected from the group containing aliphatic urethanes or a mixture of at least one radiation-curable lacquer and at least one polyurethane.

9. Method according to any of the preceding claims, characterized by the fact that the carrier material is plate-shaped.

10. Method according to any of the preceding claims, characterized by the fact that the substrate material is selected from the group comprising paper, glass, metal, foils, wood-based materials, in particular MDF, HDF and CDF boards, veneers, lacquer coatings, plastic boards, KIWI boards and inorganic substrate boards, such as cement particleboard, cement fiberboard and gypsum fiberboard.

11. Device for efficiently printing a decoration onto a substrate comprising: • a computing unit; • at least one device for applying a primer to a substrate; • at least one printing device; • at least one drying device.

12. Device according to one of the preceding claims, characterized by the fact that The device also includes a device for measuring the whiteness of a carrier material.

13. Device according to one of the preceding claims, characterized by the fact that the device continues to have a work order for the application of at least one protective layer.

14. Device according to one of the preceding claims, characterized by the fact that The device also includes a device for pressing a layered structure under pressure and temperature influence.

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