Choosing the right printing technology for your substrate

Selecting the right printing technology is essential to ensure durable, legible, and compliant product codes. From batch codes and barcodes to expiry dates, each marking must withstand the challenges of its environment and substrate. Glass, metal, plastic, and cardboard all require tailored solutions to achieve optimal results. This blog explores these challenges, compares popular technologies, and includes real-world examples to guide you toward the most efficient and cost-effective coding solution for your production needs.

Challenges across substrates

Every substrate used in packaging and product coding has unique properties that influence how codes are applied and retained. For example, glass is a smooth and non-porous material frequently used for beverage bottles and pharmaceutical vials. A common challenge is ensuring ink adheres securely even in humid environments or after exposure to extreme temperatures, such as during pasteurisation or refrigeration.

Metal substrates, like aluminium beverage cans or industrial parts, often have reflective or coated surfaces that can make achieving clear, scannable codes difficult. In the case of soft drink cans, codes must remain legible despite frequent handling and condensation during distribution and storage.

Plastics vary significantly in texture and composition. A PET bottle for a soft drink has different coding requirements than the flexible film used for snack packaging. Flexible materials present their own issues, such as stretching or smudging during handling, which can distort the printed code.

Cardboard, used for cartons and shipping boxes, is porous and prone to dust accumulation. This can affect the adhesion and clarity of printed codes, which are often crucial for logistics and inventory tracking.

Technology comparisons

To overcome these challenges, manufacturers use a range of coding technologies. Here’s how they compare, with examples of their practical applications.

Continuous inkjet (CIJ) printing

CIJ printing is a go-to solution for many industries due to its ability to produce high-speed, high-quality marks. It works particularly well on curved or uneven surfaces, making it an excellent choice for coding beverage bottles or pharmaceutical vials.

Beverage industry example: A large beverage manufacturer uses CIJ to print batch numbers on glass soft drink bottles. The inkjet system’s quick-drying ink ensures smudge-free codes even in humid environments, and its ability to operate at high speeds keeps up with the bottling line’s output.

While CIJ is versatile and reliable, it does require regular maintenance. Additionally, consumables such as ink and solvents must be replenished frequently, which can increase long-term costs.

Laser marking

Laser marking provides a permanent, tamper-proof coding solution by etching or altering the substrate’s surface. It is particularly effective on hard materials like glass and metal, as well as certain types of plastic. Laser systems are also ideal for operations aiming to reduce consumables and minimise environmental impact.

Pharmaceutical industry example: A pharmaceutical company uses laser marking to print expiration dates and unique identifiers on glass vials. The permanent mark ensures traceability throughout the product's lifecycle, even in environments where labels could be removed or damaged.

While laser marking offers durability and precision, its higher upfront cost can be a barrier for smaller operations. However, this is often offset by its low maintenance and long-term savings.

Thermal transfer overprinting (TTO)

For flexible packaging and films, TTO is the preferred choice. By using heat to transfer ink from a ribbon onto the substrate, TTO delivers high-resolution, smudge-free codes, including detailed barcodes and graphics.

Confectionery industry example: A snack manufacturer uses TTO to print QR codes on flexible pouches. The crisp, high-resolution codes allow consumers to scan for promotional offers, while the durable print withstands the rigors of transportation and handling.

TTO systems, however, generate ribbon waste, which can be a concern for companies looking to reduce environmental impact.

Drop-on-demand (DOD) inkjet printing

DOD inkjet printing is ideal for porous materials like cardboard. It releases ink only as needed, producing bold, legible marks with minimal waste. This technology is especially suited for printing large-format codes and logos on shipping cartons.

Logistics warehouse example: An e-commerce fulfilment centre uses DOD printers to print tracking barcodes and company logos on cardboard boxes. The system’s low maintenance requirements and ability to handle dusty environments make it a reliable choice for high-volume operations.

However, DOD is less effective for small, detailed codes or applications requiring high-speed output.

Key considerations for choosing your technology

When selecting a coding solution, it’s important to evaluate your specific production requirements:

Substrate compatibility: For durable marks on rigid materials like glass or metal, laser marking is ideal. For flexible or porous materials, consider TTO or DOD, respectively.

Production speed: CIJ is well-suited for fast-moving production lines, while TTO and laser marking are better for applications requiring precision.

Cost efficiency: While laser systems have a higher initial cost, their low maintenance and lack of consumables can make them more cost-effective over time.

Environmental impact: If sustainability is a priority, laser marking eliminates consumables, while modern TTO systems can reduce waste through efficient ribbon use.

Testing your chosen solution on actual substrates is crucial to ensure it meets your specific needs for adhesion, durability, and clarity. This is a service we offer here at Industrial Printer Services Ltd. If you have a substrate, send it to us and we can test and advise you on the most appropriate solution.

Summary

Choosing the right coding technology for your substrate is a critical step in ensuring compliance, traceability, and customer satisfaction. From laser marking’s permanence on glass to TTO’s precision on flexible packaging, each technology offers unique advantages tailored to specific materials. Real-world examples from industries like beverages, pharmaceuticals, and e-commerce highlight how effective solutions can overcome challenges and streamline operations.

By integrating different technologies into your production line, you can ensure that every product and package is coded accurately and efficiently, reducing downtime and improving traceability across the supply chain.

If you’re ready to explore the best coding technology for your substrates, our team is here to help. Contact us today at Industrial Printer Services Ltd and we'd be more than happy to discuss your specific requirements.

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