The answer to a coded question

Andrew Smith looks at the ongoing debate which pitches inkjet against laser coders ,and concludes that the real competition is inkjet versus inkjet and laser versus laser

For the past decade there has been one enduring question in coding circles — will laser ever steal the inkjet crown? Given the claims made for the former, this would appear to be an obvious question, but its durability as a topic of conversation is actually rather odd because the answer is simple: as long as the capital cost differential remains as wide as it currently is, the answer will be 'yes' in some circumstances and 'no' in others.

Laser technology has a lot going for it, particularly in sectors such as the pharmaceutical industry where operational cleanliness can be a vital factor. Being ink-free they are inherently more hygienic and easier to keep clean. They also offer high quality, indelibility, reliability and low running costs and with the introduction of dot matrix technology, they have become much more flexible in their capabilities.

The disadvantages, however, can be crucial when it comes to decision time. Lower coding speeds and limitations on the types of substrates which will take a laser, rule them out for some applications, but the major reason for the low installed base is cost.

a necessary evil

Coding systems are commonly perceived as a necessary evil in the sense that they are a regulatory must, but add no value to the product. Cost is, therefore, critical and at a typical capital cost premium of three to four times that of inkjet systems, lasers just do not make sense for small to medium sized users. Only sizeable companies generally have the financial capability to take a major up-front capital investment and play it off against the absence of a long-term consumables bill.

For those, however, with the financial wherewithal or a strict requirement for a clean operation, laser has considerably widened the choice and recent advances have made considerable inroads into the problems of speed, substrate incompatibility and, to some degree, cost. As a result, the majority of coding suppliers can offer both technologies, and development is continuous in what is an intensely competitive market.

However, to put the marketplace in perspective, 27 years after the first laser coder saw the light of day and ten years on from the introduction of dot matrix technology, lasers account for less than 10% of the installed base of coding systems worldwide.

Penetration of laser technology into the market has, therefore, been relatively slow, but there are encouraging signs that some steady progress is being made for certain applications. As mentioned, the qualities of cleanliness and indelibility certainly lend themselves to the pharmaceutical industry and in regions, such as the Far East where these attributes are highly regarded, the growth is encouraging.

There is also a market for the newer generation of dot matrix systems in the replacement of older mask systems. While this activity does not increase laser's market share, it does provide a revenue stream and a 'shop window' for the laser side of the business which encourages further development activity.

Markem Systems believes laser will also benefit as companies look to replace older thermal transfer or embossing systems, but are concerned over the quality and permanence of inkjet and to this end it has acquired a majority shareholding in US-based Laserlink Corporation.

The acquisition now means the company can offer a complete portfolio of coding solutions and its entry into this sector has been marked by the launch of SmartLase, which it describes as the first in a new generation of compact, low power laser coders. 'Hitherto,' says Markem's Mike Whiteoak, 'laser coders have been large, expensive, unwieldy devices, ill-suited for mounting within the confines of a cartoner.'

It does not require a PC on the factory floor and can be fully integrated with Markem's CimControl networking software. And apart from it being the most compact laser coder on the market, the company also claims SmartLase has a lower total cost of ownership than any other inkjet or laser coder. Markem expect it to prove particularly popular for marking primary cartons, sachets, labels and PET bottles.

Also with the pricing issue in mind, Marconi Data Systems has introduced the MDS Focus steered beam laser coder which it says is 'exceptional value' for lower speed applications and ideally suited to marking onto secondary paperboard packaging or labels as well as PET and PVC.

Standard features on the 1000 system include tri-line, tower and inverse print options, static or dynamic operation, serialiser, date and time inserts, a print counter, upper and lower case lettering, a 20 message, 100 character/line storage capability and two RS-232 ports for downloading software and running the user interface. It also features scalable fonts that allows character height and width to be adjusted at full production speeds.

The user interface is a hand-held terminal with alphanumeric keypad and a 4¥20 character dot matrix display which again dispenses with the need for a PC with its additional cost and footprint.

precision imaging

High reliability, low maintenance coding at speeds up to 1,070 characters/s at line speeds up to 130m/min are promised from Imaje's new Lightjet laser coder.

Moreover, the company says it has addressed the substrate problem by using a 250W laser, the most powerful currently available, which, it claims 'allows marking even on the most difficult materials'.

Manufactured by Rofin, the CO₂ SLAB sealed-tube source laser is guaranteed for three years and uses a 'high reliability polygonal mirror system'. The compact print head is mounted on an articulated arm providing 1.6m reach to simplify the integration with existing lines.

The distance between the head and the surface to be marked can be between 125 and 225mm with a tolerance of ±3mm to allow for variations in the marked surface and up to five lines of coding using character heights from 2 to 15mm in several fonts can be achieved. Standard RS-232 and 422 ports can be used to download data or manual entry is through a simple to use menu-led interface.

Domino has targeted the quality end of the market with the launch of its first high resolution laser coder. 'The DGM-1', it says, 'has been designed for optimum graphic image quality and for coding detailed information into limited areas.' It believes these will appeal to the pharmaceutical and healthcare markets.

The DGM-1 is said to provide precision imaging from less than a millimetre to full field height in TrueType fonts. Graphics can be easily imported and the Windows-based software with its familiar operating protocols provides ease of use.

For those who, for whatever reason, lean towards inkjet solutions, the development work continues and a number of companies have introduced upgraded and new products.

Marconi Data Systems suggests that companies which are looking to replace their existing thermal coders should consider the Videojet PrintPro which is said to combine 'excellent image integrity' with minimal maintenance and high productivity. It is rated for lines up to 6m/sec and eight popular bar code symbologies and a variety of TrueType fonts are provided as standard. The printer also provides time and date in different formats and features sequential numbering.

windows software

To minimise downtime, the software can provide a system of component-level diagnosis on demand and the unit incorporates teleservicing technology for direct, real-time communication with the MDS worldwide service network.

The company has also introduced the Videojet Ipro small character ink jet for which it claims better performance and lower operating costs. Design features include a 15% reduction in the throw distance to improve drop placement and provide a cleaner running printhead. It also incorporates CleanSweep, which automatically cleans the nozzle at start-up and Accudrop character generation in 5¥5 and 5¥7 matrices to improve print quality.

The intuitive, icon-based user interface uses a Windows OS and connectivity is improved through two RS232 ports and an Ethernet LAN. Networking can also be established through Windows.

The IPro uses a new 'intelligent' product detector that is said to automatically adjust sensitivity based on operating conditions and warn of impending problems.

Also new from MDS is Excel WebLink, a printer management tool which provides for remote status monitoring of one or more of its Excel series inkjet printers. The software allows the printers to be connected to a LAN/WAN, intranet or even the internet and act as a web server. This gives any standard web browser the ability to connect to the printer over a typical Ethernet connection.

The information can then be viewed from any web browser worldwide, allowing for example, the monitoring of production volumes or the internal functions of the printer for the purposes of preventative maintenance. Technical support can also be hooked up to any printer in the world to assist with troubleshooting.

A new range of 'environmentally friendly' inkjet printers has been launched by Imaje. Also described as 'all terrain' the company says they can print on virtually any surface, under the most difficult dusty, in damp and hot conditions using a variety of inks.

The five model S8 range features a pressurised printhead and new ink circuit and automatic nozzle cleaning and solvent fume condenser to ensure 'high quality coding, fast set-up and low running costs'.

The stainless steel, water resistant control cabinet has a large screen and the keyboard uses easy to understand icons to simplify set-up and changeover. An RS232 interface facilitates data download and all the models can be networked to a central computer. Inside the cabinet, a single circuit board replaces the rack-mounted electronics of previous printers reducing the number of connections to 'significantly increase reliability'.

The model range includes the S8 Classic, a simple entry-level printer, and the S8 Master which can cope with up to 16 lines. Other models have features for specific purposes. These include the high contrast printing and IP65 'wash down' protected machines.

codes on outer packaging

For outer packaging, Domino has produced the G-7000, a high definition system for codes up to 70mm high. Featuring a 500 channel print head, the inkjet coder can cope with variable, verifiable bar codes as well as graphics, which allows the purchase of generic cases in bulk for printing on-line.

The company has also just launched buydomino.com, an e-commerce site enabling the order of printers and consumables at any time, anywhere in the world. The site offers a variety of ways to search for a product, the ability to call up previous shopping baskets and it sends confirmatory emails when an order is dispatched to the customer.

Also offering a new large character printer is Mark-O-Print. The Jetcoder is said to have improved print quality, the ability to print up to four lines and much reduced ink usage. It has 224 nozzles with 32 controllable ink channels and is capable of printing 47mm high codes onto porous surfaces.

The company is currently offering 'upgrade' pricing on old valve type coders and for those yet to be convinced, a free interactive multimedia CD detailing the machine and its 'user-friendly' software is available through the company's website, mark-o-print.co.uk.

CLARiSOFT, launched at the recent Pakex, is claimed to be the first generic image design software that works with all leading makes and models of coding and labelling equipment.

Designs, incorporating dates, graphics, barcodes and text can be created, including provision for real-time information and automatic date code calculations 'to eliminate human error'.

The company says 'the ability for the first time to create a single coder independent image design across multiple lines and equipment ensures total consistency across all coding operations'.

Domino has introduced an ink of particular interest to the pharmaceutical market. Designated 767BK, the thermochromic ink changes colour from black to blue when sterilised at 120 to 125°C for 20 minutes.

MEK free, it is said to have excellent adhesion and is tolerant to water and high humidity environments. In addition to use on metals, the ink provides comparable performance when used on retortable pouches. With a drying time of 2 to 6s, depending on substrate, this high contrast ink is also said to provide excellent resistance to abrasion.

A new ink manufacturer has entered the market with the formation of SunJet by Sun Chemicals. The company will be based near Bath in Somerset, UK, where all development, bulk manufacture and sales will be centred.

As part of the world's largest manufacturer of inks coatings and organic pigments, SunJet will be supplying OEMs with a large variety of inks, including UV cured pigmented inks for drop-on-demand print heads.