Inline Digital Printing for Packaging Material
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Solution Overview
Problem
Current packaging methods for liquid consumable products using pre-printed multi-layer materials are costly for small volumes and limit design flexibility, as they require large quantities of pre-printed materials and cannot accommodate last-minute design changes, while also risking ink migration and contamination.
Innovation Solution
An arrangement that includes a digital printing system integrated with a packaging machine, allowing for customized printing on packaging material in real-time, with the printed side never coming into contact with the food-contact side, and a splicing unit for continuous operation, enabling hybrid printing and reducing ink transfer risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pre-printed packaging material reels are used, then printing quality and design consistency are improved, but manufacturing cost increases and design flexibility is reduced
Solution Approach 1:
The packaging material is pre-prepared with the food contact side (second side) ready, but the non-food contact side (first side) is left unprinted or partially printed. The digital printing system then applies final printing directly onto the packaging material just before packaging, allowing preliminary preparation without full pre-printing. This enables design changes and customization while maintaining printing quality.
Solution Approach 2:
The system transitions from static pre-printed reels to dynamic digital printing where the printing content can be changed on-the-fly. The digital printing system allows real-time customization of packaging designs, enabling adaptability while maintaining consistent print quality through digital control mechanisms.
2Productivity
If large reels of pre-printed packaging material are used, then production efficiency is improved, but storage cost and waste increase
Solution Approach 1:
The system changes the printing parameter from batch pre-printing of large reels to on-demand digital printing. This allows production to match actual demand more closely, reducing the need to store large quantities of pre-printed material and minimizing waste from unsold or outdated packaging designs.
3Quantity of substance
If the printed side of packaging material contacts the food contact side, then printing coverage is improved, but food safety is compromised due to ink migration
Solution Approach 1:
The packaging material is segmented into two distinct sides: the first side (non-food contact) for digital printing and the second side (food contact) that remains clean. The system ensures these sides do not contact each other during transport and processing, physically separating the printed surface from food contact areas to prevent ink migration while maintaining adequate printing coverage on the appropriate side.
Solution Approach 2:
The packaging machine design incorporates intermediate handling mechanisms that prevent direct contact between the printed first side and the food-contact second side. Specialized transport paths, guides, and positioning systems act as intermediaries to ensure the printed surface never touches the food contact surface, eliminating ink migration risk while maintaining printing effectiveness.
Data Source
Figure 1
AI summary
The invention relates to an arrangement adapted to package a liquid consumable product in a package. The arrangement comprises an infeed to provide prepared packaging material having a first side (6) and a second side (7) adapted to be in contact with the consumable product, a digital printing system (4) coupled to the infeed and adapted to print at least one color onto at least a portion of the first side (6) of the prepared packaging material, and a packaging machine (9) coupled to an outfeed of the digital printing system (4) and adapted to provide a package from said prepared packaging material. The package is filled with the consumable product, and the printed first side (6) of the prepared packaging material does not get in contact with the second side (7) during transport of the printed prepared packaging material from the digital printing system (4) to the packaging machine (9).