Can Laser Coding Replace TTO for Flexible Packaging?

Specialized Laser Coders for TTO Replacement

When it comes to printing variable information, such as dates, lot codes, barcodes, and more, onto flexible packaging, thermal transfer overprinters (TTO) are a well-proven technology.

Some of the TTO advantages include:

• Excellent print quality at 300 DPI
• Able to operate on both intermittent and continuous motion parent machines
• Available in print widths from about an inch to up to five inches wide
• A wide range of thermal ribbons is available to suit almost any application.
  

Despite the advantages of TTO printers, there are certainly some drawbacks as well:

• The thermal transfer ribbon is a consumable that must be procured and managed; depending on the grade needed, it can be quite expensive.
• Used ribbons need to be disposed of
• The printer needs to stop in order for the thermal ribbon to be replaced when used, causing downtime for the parent machine
• Operators often drop the ribbon cassettes, bending the rollers, which can cause ribbon wrinkles and voids in the print
• The printhead needs to be frequently cleaned and eventually replaced.

Can Laser Coders Overcome These Issues?

Laser coders have been used in flexible packaging applications for a while, but in recent years, laser manufacturers have developed coding systems with a form factor similar to a TTO printer, making it easier to replace thermal transfer with laser technology and often using the same mounting hardware.

Laser technology advantages

• No consumables needed – since no printing ribbon needs to be replenished, downtime is reduced, improving the overall efficiency (OEE)
• Maintenance and cleaning are also reduced, further improving efficiency
• More sustainable, no rolls of used ribbon to dispose of
• No risk of poor print quality due to ribbon wrinkling

Factors that need to be taken into account

• Not all materials are receptive to laser coding – it’s vital that testing is carried out
• Currently, only UV lasers are available, no fiber or CO2
• The form factor limits the available lenses and marking field sizes

Two laser manufacturers that are providing this type of equipment are Keyence and Macsa.

Keyence

Macsa

Is This Type of Laser the Best Option?

For printing on flexible packaging, several other viable technologies are available.

In addition to TTO printers, there are CO2, fiber, and UV lasers; piezo, thermal, and continuous inkjet; and even non-digital printers such as hot stamp and roller coders.

There’s no question that the specialised TTO style UV laser, as developed by Keyence and Macsa, can bring some of the advantages of laser technology, while being easy to install into existing TTO mounting hardware (to be fair, thermal inkjet printers are often installed into TTO brackets as well), but conventional laser coding systems are available in a range of wavelengths, power outputs, lens options, and marking head speeds.

My feeling is that this kind of laser system is an interesting addition to the range of alternatives that are available for flexible packaging coding. It obviously isn’t for every application, but it is a cool concept, and it will be interesting to see whether other coding solution OEMs come up with something similar.

For more information:

Keyence FP–1000 info.

Macsa iLumiFlex info