by Melissa Donovan
Advancements in printhead technology continue to change the game in terms of how and when inkjet printing is used for corrugated packaging. The newest devices offer high-quality print while saving corrugated plants money and time.
Above: The Domino X630i digital aqueous inkjet corrugated press.
Past to Present
In the past, inkjet was not able to provide the quality, reliability, or speed that corrugated package printing required. Today, we are well on our way with digital hardware meeting analog technology in all three categories.
According to Kristen Minlschmidt, product marketing manager, HP Inc., when digital printing entered into corrugated production in the early 2010s with multi-pass inkjet technologies it enabled high print quality, but this was at the expense of production speed.
Nevertheless, the attraction of digital was there. “Early users of the technology were quick to migrate low-volume, high-value applications where even a limited production speed could generate returns,” explains Minlschmidt.
Throughout the late 2010s, engineers worked hard to “significantly improve production speeds while retaining high quality by using single-pass inkjet. This improvement reduced production costs and allowed converters to economically produce higher volume orders. As the technology continues to rapidly advance, inkjet is now a transformative solution that’s swiftly changing the dynamics of box production,” admits Minlschmidt.
Jochen Sproll, strategy and business development manager, Koenig & Bauer Durst GmbH, agrees, stating that with the water-based inks and high-resolution printheads found in printers like Koenig & Bauer Durst’s Delta SPC 130, quality, reliability, and efficiency standards are met.
“Historically, inkjet printing faced challenges in meeting the quality, reliability, and speed demands of corrugated package printing. However, advancements over the past decade have significantly bridged this gap,” adds Bill Myers, marketing manager, Domino North America.
Neil Cook, business development manager, Xaar plc., believes “inkjet technology can meet and even surpass analog printing in many cases, providing the added benefits of digital flexibility, customization, and sustainability.”
Independent, peer-reviewed research from Swansea University’s Welsh Centre for Printing and Coating back up Cook’s statement. Its study validated the impact of Xaar’s Ultra High Viscosity Technology with its Aquinox printhead, which can jet fluids of up to 1,000 centipoises at ambient temperature.
The study reported up to a 67 percent increase in color density on coated white corrugated substrates, achieving more vibrant prints without additional processing. The high-viscosity inks used also matched the intensity of conventional inks but required less volume, needing up to 50 percent less ink than standard viscosity inks on both primed and unprimed media. This translates into faster drying times and lower energy consumption.
Corrugated Board Challenges
Corrugated board presents unique challenges, for example printhead nozzles may get blocked from dust. Luckily, inkjet manufacturers are eliminating or at least minimizing these issues.
First, we must understand how crucial it is that the printer is placed in a clean and controlled environment. “The clean room not only protects the print engine from corrugated dust, it also creates a stable environment related to temperature and humidity,” shares Chuck Slingerland, VP, Barberan Corrugated NA.
Automated cleaning and capping systems are key to preventing or minimizing printhead nozzle blockages from cardboard dust. The Domino X630i includes the i-Tech CleanCap, an automated cleaning and capping system that reduces maintenance needs and ensures consistent print quality.
Xaar’s TF Technology also ensures continuous ink recirculation, reducing nozzle blockages from cardboard dust and maintaining reliability in high-production environments.
“Dust, board warp, and inconsistent stacking are challenges,” lists Sproll. Koenig & Bauer Durst addresses them with a forgiving feeder, pre-print sheet cleaning, and tight control of board quality throughout production.
The physical nature of corrugated board is unwieldy and complicated. “Corrugated substrates vary in texture, thickness, and absorbency, which can directly impact print quality and consistency. Ink absorption into the substrate was always a challenge, leading to duller colors and increased ink usage,” explains Cook. Xaar’s Ultra High Viscosity Technology addresses this as the pigment in high-viscosity fluids sits on the surface rather than being lost to absorption, resulting in more vibrant and opaque prints.
Minlschmidt also suggests variability in board/paper thickness, warp, surface texture, and moisture content as challenges that can complicate achieving consistent ink application and image quality when printing to corrugated board.
HP technology is designed with these challenges in mind. Printhead designs, featuring improved nozzle protection and ink recirculation systems, minimize the impact of dust and ensure reliable ink delivery. Board handling capabilities and precise tension control accommodate a range of board/paper thicknesses and surface variations.
“In addition, cardboard is full of air and has uneven printing surfaces,” notes Philip Chu, product manager – UV printers, Roland DGA Corporation.
Printheads on the Case
Printhead improvements advance inkjet in corrugated package printing.
Historically, first generation, single-pass printheads were limited, operating at 360 dpi with large droplet sizes in the range of 12 to 13 picoliters, according to Slingerland. “In contrast, second generation printhead technology offers significantly higher resolution and much finer droplet sizes, enabling sharper detail and more lithographic-like image reproduction.”
A printhead efficiently jetting fluids is a key component to inkjet reaching analog speeds, precision, and quality. “Xaar’s printhead technology enables the jetting of much higher viscosity fluids than ever before. This innovation redefines what’s possible for users, unlocking new opportunities in print, and setting a new standard for the industry,” explains Cook.
“Advanced piezoelectric printheads with recirculation ensure uptime, precision, and long-term stability—even in 24/7 operations. They’re key to minimizing clogging and supporting high-speed, high-resolution printing,” says Sproll.
The newest iterations of HP Thermal Inkjet printheads offer high nozzle density, scalability, and reliability, which enable high-speed, high-resolution printing. HP’s latest generation industrial printhead technology on the PageWide T1195i and T700i Presses offer improved reliability that benefits system productivity and reduces operating costs all around.
Printheads and precision go hand in hand. “Advancements in printhead technology are pivotal for inkjet printing in corrugated packaging. The Domino X630i utilizes i-Tech StitchLink technology, which ensures precise alignment of printheads, delivering seamless and high-quality prints across the substrate. This precision enhances image quality and reduces setup times,” states Myers.
Further Advancement
Besides printheads, other components of the corrugated printing process advance inkjet.
Ink updates are one. “Water-based white ink—including Koenig & Bauer Durst digital water-based white for corrugated substrates in primary food packaging, as well as efficient drying systems and workflow automation are driving performance, flexibility, and sustainability,” says Sproll.
“The Domino AQ95 aqueous ink set enables printing on both coated and uncoated corrugated materials without the need for pretreatment, expanding application possibilities,” says Myers.
Cook cites Nazdar’s HighV Aqua Coro high-viscosity water-based ink, which minimizes absorption into the board to deliver superior color vibrancy and reduce overall ink usage. “Since less ink soaks into the substrate, graphics printed in a single pass appear significantly more striking compared to those using standard viscosity inks.”
“These benefits are relevant for corrugated packaging, where high-viscosity inks enable a broader color gamut without the need for coating or primer, reducing costs and resource usage while improving efficiency. Additionally, by reducing water content in inks, drying energy requirements are lowered. This makes the process more efficient and environmentally sustainable,” continues Cook.
Another important component is fluid management systems from companies like Megnajet. “These are also important for advancing inkjet for corrugated printing by maintaining optimal ink conditions throughout long print runs, ensuring consistency and reliability,” says Cook.
Inspection systems help to eliminate registration errors. Barberan S.A. employs its proprietary MasterVision camera inspection system which not only aligns printheads automatically, but also enables real-time monitoring of print quality to ensure consistent output, notes Slingerland.
Workflow plays a role. “HP One Package software is designed to leverage digital efficiency and flexibility, while effectively connecting an HP PageWide Press with existing factory systems. With the HP One Package software, converters have a wide choice of proven HP and partner solutions to support every stage of the digital print workflow,” explains Minlschmidt.
Automation
Driving efficiency across the entire corrugated production configuration is automation, whether it’s on the back or front end of the process.
“To ensure a smooth transition to digital printing for corrugated production, converters place a premium on preserving operational efficiency and minimizing costly disruptions to established workflows. Automation emerges as a strong enabler of this goal, driving efficiency gains through streamlined processes, reducing manual interventions, and improving consistency,” notes Minlschmidt.
Automation is pivotal. “Automation directly boosts efficiency and productivity. The corrugated industry isn’t looking for gimmicks. Converters demand performance, cost efficiency, and consistent quality. A smooth and reliable printing process is essential, but it’s just one link in the packaging supply chain that helps brand owners attract attention and win over their consumers,” shares Sproll.
“Automation in media handling and finishing streamlines production, reduces manual intervention, and enhances efficiency,” adds Myers.
Chu agrees. “Increased automation as well as other front- and back-end improvements translate to increased speed and efficiency, which means faster turnaround times. Proper material treatment and handling makes everything faster.”
Into Future Use
Inkjet is changing how corrugated board is printed. Compared to a decade ago, speed and quality have matured considerably thanks to advancements in printheads, inks, and automation components.
Jun2025, Industrial Print Magazine
