Digital Single Pass Printer Applications

Water-Based Single-Pass Digital Printers: An Efficient and Eco-Friendly New Driver Empowering the Packaging and Printing Industry

Against the backdrop of the global packaging industry's transformation towards greenization and flexibility, digital printing technology has emerged as a core engine for industrial upgrading, thanks to its advantages such as no plate-making requirement and rapid response. Among various digital printing technologies, water-based single-pass digital printers, which integrate eco-friendly water-based inks with high-speed single-pass imaging technology, hold significant potential in the printing field of non-waterproof paper packaging and related flexible materials. They provide efficient and safe printing solutions for industries including food and e-commerce.

Compared with the repeated overprinting of traditional multi-pass printing, water-based single-pass digital printers complete full-color printing in one go through a high-precision nozzle array. Combined with low-VOC (Volatile Organic Compounds) eco-friendly water-based inks, they not only address the issues of cumbersome processes and limited production capacity in traditional printing but also comply with global environmental regulations. Their core advantages are distinct:

• High Speed and Efficiency

With a printing speed ranging from 40 to 150 meters per minute, the daily production capacity can reach hundreds of thousands of pieces, making them suitable for mass production.

• Safety and Environmental Friendliness

The water-based inks meet international standards such as the EU EuPIA (European Printing Ink Association) standards and food contact regulations, being odorless and free from harmful migration.

• Precision and Stability

Relying on intelligent color calibration and high-precision nozzle technology, they achieve high-definition output with a resolution of over 1200 dpi, and the color registration error is less than 0.1 mm, ensuring excellent color consistency across batches.

Core Application Areas: Full-Scenario Coverage Focused on Non-Waterproof Paper Packaging

Their application scenarios focus on non-waterproof paper packaging and related flexible materials, accurately matching the needs of multiple industries and forming four core application areas:

1. Food Packaging Field: Dual Guarantee of Safety and Efficiency

Food packaging has strict requirements for printing safety and efficiency. The food-grade water-based inks used by water-based single-pass digital printers comply with the EC 1935/2004 framework regulation and standards of brands like Nestlé, avoiding the risk of harmful substance migration from the source. Their high-speed printing capability can perfectly meet the mass production needs of food packaging such as bread paper bags, fast-food handbags, and snack paper outer boxes.

Application Case: A fast-food chain launched a personalized handbag project, requiring the printing of multiple batches of different patterns in a short period. After introducing water-based single-pass digital printers, it achieved fast delivery within 8 hours, which was an 89% reduction compared to the 72-hour cycle of traditional printing. The equipment operated stably at a speed of 80 meters per minute, with a daily production capacity of over 200,000 pieces. The printing resolution reached 1200 dpi, featuring vivid colors, and the water-based inks were odorless and met safety requirements. Data showed that the comprehensive printing cost of the project was reduced by 37%, and VOC emissions were decreased by 82%, achieving a win-win situation in terms of benefits.

2. E-Commerce Packaging Field: A Flexible Production Tool for On-Demand Customization

The development of the e-commerce industry has driven the flexible transformation of packaging, and brand owners have an increasing demand for personalized express cartons and packaging bags. The plate-free printing feature of water-based single-pass digital printers enables single-carton, unique-version personalized printing, allowing the integrated printing of brand logos, marketing copy, and other information. Meanwhile, they are compatible with common e-commerce paper materials such as corrugated yellow and white kraft paper and coated paper.

Application Case: A well-known packaging enterprise introduced water-based single-pass digital printers and built an automated on-demand carton production system, integrating full-color printing and carton forming into a single process. It only takes 6 seconds to complete a customized carton, simplifying the traditional seven-step manufacturing process. The equipment supports printing on F-flute to three-layer cardboard, with a maximum speed of 100 meters per minute and a precision of 1200 dpi. It can customize cartons for different brands in real time and also create new revenue streams through the advertising spaces on cartons.

3.Paper Publications and Cultural and Creative Paper Products Field: A High-Quality Choice for High Definition and Environmental Friendliness

Paper publications (such as picture books and journal inner pages) and cultural and creative paper products (such as postcards and bookmarks) have high requirements for printing environmental friendliness and color reproduction, which are in line with the characteristics of water-based single-pass digital printers. These printers can accurately reproduce the details of graphics and texts. The advantages of odorless and low-VOC water-based inks enhance the user experience, and they are also suitable for the small-batch and multi-style production needs of cultural and creative products.

Application Case: A cultural and creative enterprise launched an environmental protection-themed cultural and creative printing project for Christmas, mainly producing Christmas greeting cards, bookmarks, and postcards. After introducing this equipment, it was compatible with 80-157 g/m² non-waterproof eco-friendly paper (not applicable to coated paper and offset paper) and operated stably at a speed of 30 meters per minute, with a daily production capacity of 14,400 sets (calculated based on each set containing 1 greeting card + 1 bookmark + 1 postcard, each with a size of 15×10 cm, and an 8-hour working day). The equipment supports the rapid switching of 12 festive patterns such as Christmas snow scenes, reindeer, and Christmas trees without stopping for adjustments, with a minimum order quantity of 800 sets for a single style. The 1200 dpi high-precision printing reproduces the delicate details of the patterns, and the natural luster of the water-based inks makes the cultural and creative products more textured. Additionally, the odorless and eco-friendly properties meet the safety requirements of holiday gifts. After the project was launched, the sales volume of this series of Christmas cultural and creative products increased by 45% compared with those produced by traditional printing, and the proportion of small-batch customized orders increased to 30%.

4.Wooden Packaging and Decorative Material Field: An Efficient Printing Solution for Natural Texture

Wooden packaging (such as red wine wooden boxes and tea wooden boxes) and decorative wooden panel paintings are mostly made of uncoated and non-waterproof substrates. The natural materials are highly compatible with the eco-friendly inks of water-based single-pass digital printers. These printers can achieve high-definition printing on the wooden surface, endowing the wood with personalized designs while retaining its natural texture. Moreover, the water-based inks are odorless, safe, and eco-friendly, meeting the requirements of high-end wooden packaging, and their high-speed performance is suitable for mass production.

Application Case 1: A high-end red wine brand launched a customized solid wood red wine box project, requiring the printing of logos, production area maps, and anti-counterfeiting codes on pine boxes. After introducing this equipment, mass and efficient printing was realized. It is compatible with solid wood boards with a thickness of 10-20 mm, and the speed of 30 meters per minute enables a daily production capacity of over 5,000 pieces. The 1200 dpi precision ensures clear and uniform patterns, and the ink adheres closely to the wood, featuring wear resistance and durability during transportation.

Application Case 2: A home furnishing enterprise uses this equipment to produce decorative wooden panel paintings. It can quickly switch patterns and support personalized customization, with a minimum order quantity of 1 piece for a single style and no upper limit. The equipment retains the wood texture and meets environmental standards, and the profit margin is increased by 99.99% compared with traditional hand-painted products.

Technological Iteration and Future Trends: Expanding Application Boundaries through Core Performance Upgrades

Technological iteration is driving water-based single-pass digital printers to develop in the direction of higher efficiency, greater flexibility, and wider compatibility. Core performance continues to be upgraded. In addition to the improvement of printing speed, the printers also have multi-task continuous printing and variable data printing functions. The former realizes seamless order switching and improves production continuity; the latter supports the real-time printing of dynamic information such as batch numbers and anti-counterfeiting codes, meeting the needs of food traceability, e-commerce logistics, and other fields.

As one of the earliest domestic manufacturers engaged in the R&D and production of single-pass digital printers, Sunthinks has achieved outstanding performance in its products, ranking first in global sales. It offers two printhead configurations: the HP A3 configuration meets the needs of conventional mass and efficient production; the Epson I3200 configuration, relying on PrecisionCore piezoelectric technology, achieves higher-precision output, more accurate ink droplet control, and smooth color transitions, suitable for fine printing needs. Furthermore, breakthroughs in water-based ink technology are expanding application boundaries. In the future, it is expected to enter the field of intelligent packaging such as anti-counterfeiting traceability and temperature-sensitive patterns.

For purchasers, choosing water-based single-pass digital printers is a strategic layout to conform to the environmental trend and improve market response capabilities. When selecting models, key factors to focus on include the safety and compliance of inks, the matching degree of equipment speed and precision, the adaptability of core functions, and the technical support from manufacturers. At present, Sunthinks' single-pass printing solution has undergone 8 years of technical refinement, featuring stable equipment performance, comprehensive after-sales services, and customizable services. Among them, Sunthinks has become a preferred choice for purchasers due to its early R&D advantages, core functions of multi-task continuous printing and variable data printing, and market recognition of ranking first in global sales.

During the critical period of the green and digital transformation of the packaging and printing industry, water-based single-pass digital printers have become a new driver for industrial upgrading with their advantages of high efficiency, environmental friendliness, and flexibility. They accurately meet the needs of multiple industries such as food, e-commerce, paper cultural and creative products, and wooden packaging, realizing cost reduction, efficiency improvement, and brand upgrading. In the future, with the advancement of technology, their application scenarios will be further expanded, creating greater value for the packaging industry.