“3D Print” Embossing on Glass by Digitally Layering Viscous Inks

A recurring theme at drupa this year—everywhere in packaging, really—has been collaboration across the value chain. We saw evidence of this with the collaboration between digital printing and case right-sizing, specifically Packsize’s right-size case erecting and EFI’s digital printing technology.

Another example, what stakeholders call “game-changing” digital ink and digital printhead tech, is a collaboration between printhead manufacturer Xaar, ink manufacturer Marabu, and digital print, decoration, and embellishment OEM Kamman (a Koenig & Bauer company).

Combining Xaar's ultra-high viscosity ink printheads, Marabu's ultra-high viscosity inks, and Kammann's digital printing equipment, it’s now possible to create embossed effects on glass bottles and other packaging at a laydown (ink layer) build height up of to 3 mm, without compromising on the intricate details of the embossing or sharp contour edges of glass. 

On the equipment side, Xaar’s ultra-high viscosity inkjet tech works with Kamman's K15 and K20 decorative print machine families. Using the new high viscosity fluids developed by Marabu, Kammann’s machines allow personalized embossed effects on glass bottles, plastic and metal containers at. This latest development is entirely "backwards compatible" with in-market machines, so existing machines can jet at greater viscosity and carry a significantly increased pigment load, delivering more color vibrancy and capturing fine details with up to 50% less ink.

“Our partnership with Kammann and Marabu is a testament to what can be achieved when industry leaders unite. This breakthrough in Marabu’s ink technology, facilitated by Xaar’s high viscosity innovation and Kammann’s machine expertise, is set to revolutionize the market by defining new standards for decorative digital inkjet printing,” said Xaar’s group R&D director, Karl Forbes.

Markets include cosmetics, spirits, mass customization

The three stakeholders say that ultra-high viscosity inkjet technology is providing many manufacturers with an array of new and practical production possibilities by enabling a much wider range of fluid viscosities and chemistries to be printed at around 100 centipoises (cP) at jetting temperature, equating to approximately 1000cP at ambient temperature. A lot of markets stand to benefit, including automotive among others.

The tech stands to impact  CPG markets including cosmetics, nutraceuticals, and high-end spirits.

Another use case might be personalization, mass customization projects, or batch-size-of-one, where names or personalized, embossed messaging could be "3D-printed" to a bottle. Consider a gift or short run celebratory bottle of high-end whisky with personalized embellishments marking a special occasion, person, or event. 

At the booth at drupa

At the booth, we spoke to from Holger Tiemann, area sales manager at Kammann, and Charlotte Baile, head of marketing at Xaar. Tiemean said that process involves a pre-treatment on the glass bottles that include flame and Pyrosil® treatments, as well as a solvent primer, prior to adding inks. Clear ink is next, then white, then CMYK colors.

“And then we print the embossing. It’s a digital UV ink that we print with the Xaar head in several layers,” he said. “You print, you dry, you print, you dry, and we can can continue to do that up to three millimeter high...”Graduated ink application on a sample cosmetics jar.

"Normally you have to print, and then you have to pin the ink. Using LED UV only for a quick moment, that ink will not flow; it will be stable. And with the new ink from Marabu, we don't need this. It's a high-viscosity ink and we have to pin the white, and then CMYK, no pinning; and then final curing. This is unique." 

A topcoat is then printed on top of the embossing for mechanical resistance. While this mechanical resistance can mean dishwasher safety for glass cups for use in the home, it also serves to protect glass bottles during filling and packaging you print bottles.

“When we print, we don't move the head. We move the bottle under the head. The only thing what we do is we move the head for the printing height,” Tiemann said. “I would say the Xaar printhead is the only head who can print with a gap up to 10 millimeters between it and the bottle.”

ink effects can include glossy or matte, any percentage of ink from 0% to 100%, and also in a graduated color appearance.