Printing on non-porous surfaces like plastics, coated cardboards, and vinyls presents a distinct set of challenges.
Unlike papers and fabrics, those materials resist ink absorption, which is why inks must adhere to the surfaces through solvent evaporation rather than absorption, requiring specialised printing techniques.
By understanding the challenges of printing on such specialised substrates, you can significantly improve and master print results with a flawless finish.
Let’s start exploring the best practices now!
Understanding Non-Porous Surfaces in Industrial Printing
Non-porous materials are characterised by their inability to absorb liquids or inks due to their impermeable nature. These kinds of materials do not have microscopic pores, unlike papers and fabrics, which resist liquids.
They also typically have smooth characteristics compared to porous materials, which makes it difficult to hold the inks better. These surfaces prevent inks from seeping in, so it can be hard to achieve long-lasting print results.
This lack of absorbency requires printing technologies to employ specific methods to ensure the inks adhere properly to the surface without fading or smudging.
However, despite this limitation, these materials often offer greater durability to withstand harsh conditions, especially in sectors with strict regulatory standards like the meat industry.
Read About: Optimized Batch Printing Solutions for the Meat Processing Industry
Challenges of Printing on Non-Porous Surfaces
As traditional printing techniques mostly rely on the ability to absorb the ink, impermeable surfaces come with unique challenges for industrial printing.
Let’s find out what those key challenges are by reading the explanation below.
Ink Adhesion Issues
As we know that non-porous materials tend to have ink absorption issues, which might only sit on the surfaces without proper adhesion. If this occurs, it can result in poor print quality that is prone to fading, smudging, and peeling over time.
Drying Time and Curing
The inability of inks to absorb into impermeable materials means it stays longer on the surface and takes much longer to dry. As drying time increases, the likelihood of unintentional marks also rises, particularly in high-speed, high-volume production settings.
Environmental Factors
Aside from ink absorption, environmental factors like humidity and temperature can affect the printing results of non-porous surfaces.
Temperature fluctuations, for instance, can significantly impact the curing and drying processes. Low heat may delay the inks curing, while high temperature may present premature drying.
Moreover, excess moisture in humid environments can alter coating durability and interfere with ink adhesion, leading to inconsistent results.
For these reasons, managing the humidity in the printing area is highly important for achieving perfect print results on such challenging substrates.
Print Quality and Precision
Maintaining sharp accuracy is a significant challenge for printing on non-porous substrates due to the smooth nature.
Unlike porous surfaces, these materials may cause ink to spread, reducing colour accuracy—particularly in multi-coloured prints with intricate designs.
Best Practices for Printing on Non-Porous Surfaces
Overcoming challenges of printing on impermeable surfaces involves essential practices. But, how can a manufacturer address these challenges?
The following overview will help you navigate the main challenges in industrial printing, let’s explore!
Choosing the Right Ink
The right type of inks used for these challenging surfaces determines how well the inks adhere and how long the prints will last.
UV inks are considered among the most effective options for non-porous materials, as they can dry instantly and form durable bonds to smooth surfaces like plastics, glass, and metals.
For environmentally friendly options, eco-solvent inks also offer good adhesion with less odour compared to traditional solvent inks.
However, remember to always check and verify that the chosen ink is compatible with your impermeable surfaces, as different materials may need different types of inks for optimal durability.
Surface Preparation Techniques
To ensure proper ink adhesion on non-porous surfaces, apply surface preparation techniques such as removing dust, oils, and other contaminants from the substrates.
After that, you can apply a primer for certain plastic and metal materials as it can improve adhesion and ensure the prints last longer.
For materials that do not hold ink well, surface abrasion treatment can make the surface more receptive to inks and improve adhesion as well.
Selecting the Right Printing Technology
Choosing the appropriate printing technology plays a crucial role in achieving optimal print quality. One highly recommended and widely used method for this purpose is inkjet printing.
Some types of inkjet printers are designed specifically for challenging surfaces. It is a digital printing process that employs non-contact technology or without physical contact between materials’ surfaces and the print heads.
When combined with the right inks, it can deliver precise, high-quality results on plastics, glass, and other impermeable surfaces.
Read About: Exploring Non-Contact Printing: Why Inkjet Technology is the Future
Optimizing Printing Parameters
Optimizing printing parameters includes enhancing the temperature, speed, and drying process to enhance the efficiency and print quality.
Adjusting the printing speed is essential to avoid ink smudging issues, while controlling the temperature is crucial for ink drying effectively.
By balancing these parameters meticulously, you can enhance the overall process of printing on challenging surfaces and ultimately avoid any defects and improve the print quality.
Industries Benefiting from Non-Porous Surface Printing
Several industries, such as packaging, automotive, electronics, and pharmaceuticals benefit from impermeable surface printing because of its durability.
In the packaging industry, non-porous printing is commonly used for product labels. The automotive and electronics industries, similarly, employs it for branding, printing logos and promotional products.
Meanwhile, the pharmaceutical industry relies on this printing method to label equipment and ensure durability through sterilisation processes and compliance with strict industry standards.
Achieve High Quality Printing Results on Non-Porous Materials with Inkjet Printers!
Printing on non-porous surfaces comes with challenges for several industries.
Effectively managing challenges such as ink adhesion, drying and curing, environmental factors, and print quality is essential for achieving optimal results in your business.
In addition to employing the best practices, staying up to date with the latest printing technology is the fundamental way to enhance product quality and ensure customer satisfaction.
Inkjet printers, as one of the notable printing technologies, can be your perfect choice to stay ahead of the business. Upgrade to inkjet today and see a complete list of continuous inkjet printers here.
References
https://handheldinkjet.com/what-do-you-need/what-are-you-printing-on/non-porous-surfaces/
http://www.theprintinginkcompany.ca/image/pdf/TB-08.21%20Non-Porous%20%20-%202%20PGS.pdf
https://zodia.ca/2017/01/10/guides-to-printing-on-non-porous-substrates/
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