The continuous advancement of nozzle technology is constantly changing the application methods and timing of inkjet printing for corrugated packaging. The latest equipment not only provides high-quality printing effects, but also saves considerable costs and time for corrugated box factories.
   Past and Present
    In the past, inkjet printing faced challenges in terms of quality, reliability, and speed in the field of corrugated packaging. However, today's digital hardware and analog technology have made significant leaps in all three aspects.
    According to Kristen Minschmidt, Product Marketing Manager at HP, when digital printing entered the corrugated box production field through multi-channel inkjet technology in the early 2010s, it achieved high-quality printing but sacrificed production speed. Nevertheless, the appeal of digital printing still exists. Early users of this technology quickly turned to small batch, high-value applications where even limited production speeds could bring returns, "explained Ming Schmidt.


    In the late 2010s, engineers worked hard to significantly improve production speed while maintaining high quality through the use of single channel inkjet technology. This improvement reduced production costs and enabled processors to economically produce larger quantities of orders. With the continued rapid development of technology, inkjet technology has now become a transformative solution that is rapidly changing the landscape of cardboard box production, "acknowledged Ming Schmidt.
    Johann Sproul, Strategy and Business Development Manager at Konigsegg&Ball DeShi, agrees with this, pointing out that printing machines like Konigsegg&Ball DeShi's Delta SPC 130 use water-based ink and high-resolution nozzles, which can meet quality, reliability, and efficiency standards. Historically, inkjet printing has faced challenges in meeting the quality, reliability, and speed requirements of corrugated packaging printing. However, progress over the past decade has significantly bridged this gap, "added Bill Myers, Domino's North American Market Manager.
Neil Cook, Business Development Manager at Searle, believes that "inkjet technology can achieve or even surpass analog printing in many cases, bringing additional advantages such as digital flexibility, customization, and sustainability." An independent peer review conducted by Swansea University's Welsh Printing and Coating Center confirms Cook's viewpoint. This study validates the effectiveness of the Seer ultra-high viscosity technology and its AquiNOx nozzle, which can spray liquids up to 1000 centipedes at room temperature.
    The research report shows that on white coated corrugated paper substrates, color density can be increased by up to 67%, and more vivid printing effects can be obtained without additional processing. The strength of the high viscosity ink used is also comparable to traditional ink, but requires less amount, whether on media treated with or without primer, the required amount is 50% less than standard viscosity ink. This means faster drying time and lower energy consumption.
   Challenges and Solutions in Corrugated Paperboard Printing
    Corrugated cardboard printing faces unique challenges, such as nozzle clogging by dust. Fortunately, inkjet printer manufacturers are eliminating or at least minimizing these issues as much as possible.
    Firstly, we must recognize the importance of placing the printing press in a clean and controlled environment. Cleanrooms not only protect printing systems from corrugated cardboard dust, but also create an environment with stable temperature and humidity, "said Chuck Slingland, Vice President of Barberand.
    The automatic cleaning and sealing system is the key to preventing or minimizing cardboard dust from clogging the nozzle. Domino's X630i is equipped with the i-Tech CleanCap automatic cleaning and capping system, which reduces maintenance requirements and ensures consistent printing quality. Seer's TF technology can also ensure continuous ink circulation, reduce nozzle clogging caused by cardboard dust, and maintain reliability in high-yield environments.
    Dust, cardboard warping, and uneven stacking are all challenges, "Sproul pointed out. Konishi&Bauer DeShi solves these problems through high-capacity misfeeding equipment, pre press paper cleaning, and strict control of cardboard quality throughout the entire production process.
    The physical properties of corrugated cardboard make it bulky and complex. The texture, thickness, and absorbency of corrugated cardboard vary, which directly affects printing quality and consistency. Ink absorption by the substrate has always been a challenge, leading to dull colors and increased ink usage, "Cook explained. Seer's ultra-high viscosity technology solves this problem by allowing pigments in high viscosity liquids to remain on the surface rather than being absorbed and lost, resulting in brighter and more opaque printed materials.
Ming Schmidt also pointed out that changes in cardboard/paper thickness, warping, surface texture, and moisture content are also challenges that affect achieving consistent ink application and image quality during corrugated cardboard printing. The design of HP technology fully considers these challenges. The nozzle design adopts improved nozzle protection and ink circulation system, minimizing the influence of dust and ensuring reliable ink delivery. The cardboard processing capability and precise tension control can adapt to various thicknesses and surface variations of cardboard/paper. In addition, the cardboard is filled with air and the printing surface is uneven, "said Philip Chu, product manager of Roland UV printing machines.
   The leap of nozzle technology
    The improvement of nozzles is the core driving force behind the development of inkjet technology in corrugated packaging printing.
    Slingland stated that historically, the performance of the first generation single channel nozzles was limited, with a running resolution of 360 dpi and ink droplet sizes ranging from 12 to 13 picoliters. In contrast, the second-generation nozzle technology provides significantly higher resolution and finer droplet sizes, enabling clearer details and image reproduction closer to offset printing
    The efficient inkjet nozzle is a key component for achieving simulation speed, accuracy, and quality in inkjet technology. Saier's nozzle technology is capable of spraying ink with higher viscosity than ever before. This innovation redefines the possibilities for users, opens up new opportunities in the printing industry, and sets new standards for the industry, "Cook explained. Advanced piezoelectric recirculation nozzles ensure normal operating time, accuracy, and long-term stability - even in all-weather operation. They are key to minimizing blockages and supporting high-speed high-resolution printing, "said Sproul.
    The latest generation of HP thermal inkjet heads features high nozzle density, scalability, and reliability, enabling high-speed and high-resolution printing. The latest generation of industrial nozzle technology used on HP PageWide T1195i and T700i printing machines has improved reliability, thereby increasing system productivity and comprehensively reducing operating costs.
The nozzle and precision are inseparable. The advancement of nozzle technology is crucial for inkjet printing of corrugated packaging. Domino's 630i uses i-Tech StitchLink technology to ensure precise nozzle alignment, enabling seamless and high-quality printing on the entire substrate. This precision improves image quality and shortens setup time, "Miles said.

   promoted the development of inkjet printing. 
    The update of ink is one of them. Water based white ink - including Konigsegg&Bauer DeShi digital water-based white ink for primary food packaging corrugated paper substrates, as well as efficient drying systems and workflow automation, is driving performance, flexibility, and sustainability, "said Sproul.
    Domino's Q95 water-based ink set can be printed on coated and uncoated corrugated paper materials without pre-treatment, expanding its application possibilities, "Myers said. Cook cited Nazdar's HighV Aqua Coro high viscosity water-based ink, which minimizes ink absorption by cardboard, providing excellent color vividness and reducing total ink usage. Due to the reduced degree of ink infiltration into the substrate, the graphic effect of single channel printing is more prominent compared to printing using standard viscosity ink.

    These advantages are crucial for corrugated packaging, as high viscosity ink can achieve a wider color gamut without the need for coating or primer, thereby reducing costs and resource  consumption while improving efficiency. In addition, by reducing the moisture content in the ink, the energy required for drying can be lowered. This makes the entire process more efficient and environmentally sustainable, "Cook continued.
    Another important component is the fluid management system from companies such as Megnajet. These systems are also crucial for advancing inkjet printing technology for corrugated cardboard, as they can maintain optimal ink conditions over long periods of printing, ensuring consistency and reliability, "Cook said. The detection system helps eliminate registration errors. Slingland pointed out that Babelan uses its proprietary MasterVision camera detection system, which not only automatically calibrates the nozzle, but also monitors the printing quality in real time to ensure consistency in output.
    The workflow plays an important role in it. Ming Schmidt explained that the HP One Package software aims to fully utilize digital efficiency and flexibility, while effectively connecting the HP PageWide printing press with existing factory systems. With the help of HP One Package software, manufacturers can choose from a variety of proven HP and partner solutions to support every stage of the digital printing workflow. ”
    Whether it is the backend or frontend of the process, automation is the key to improving the efficiency of the entire corrugated cardboard production configuration. In order to ensure a smooth transition from corrugated cardboard production to digital printing, processors attach great importance to maintaining operational efficiency and minimizing costly disruptions to existing workflows. Automation is a powerful driving force for achieving this goal, as it improves efficiency by simplifying processes, reducing manual intervention, and improving consistency, "Ming Schmidt pointed out.
    Automation is crucial. Automation directly improves efficiency and productivity. The corrugated box industry is not pursuing gimmicks. Manufacturers are pursuing performance, cost-effectiveness, and consistent quality. A smooth and reliable printing process is crucial, but it is only one link in the packaging supply chain that helps brands attract attention and win consumer favor, "Sproul shared. The automation of media processing and post press processing simplifies the production process, reduces manual intervention, and improves efficiency, "Miles added. Chu agrees with this. The increase in automation and other improvements in the front-end and back-end translate into increased speed and efficiency, which means faster turnaround times. Proper material handling and processing can make everything faster
    In summary, inkjet printing is changing the printing method of corrugated cardboard at an unprecedented speed. Compared to ten years ago, thanks to continuous advancements in nozzles, ink, and automation components, the speed and quality of inkjet printing have significantly improved, bringing revolutionary changes to the corrugated packaging industry.