DIGITAL PRINTING ON PVC PROFILES - WHY INKJET IS A COST-EFFICIENT ALTERNATIVE TO FOIL WRAPPING ?

This article kicks off a series in which I’ll explore two competing technologies for PVC profile decoration:

• the traditional method of foil wrapping and
• the new approach of inkjet printing.

Foiling has been the industry’s standard for years, but recent advancements in inkjet technology are starting to change that. Throughout this series, I’ll be analyzing various aspects of both technologies to show why digital printing direct to PVC profiles became an attractive alternative. Today, I’ll focus on the cost side, looking at how inkjet printing offers significant savings compared to the foil wrapping process.

1. Higher Production Efficiency

Inkjet printers are significantly more efficient than foil-wrapping machines. While wrapping machines require extensive setup time and constant adjustments, inkjet printers are programmed with the profiles and automatically recognize each one. This means no manual setup or adjustments are needed for each batch or design change. The printer digitally adjusts all settings, including the print file, saving time and allowing for a smoother, faster production flow.

The production efficiency of an inkjet printer can be at least twice that of a foil-wrapping machine, allowing manufacturers to produce more profiles in less time. This increased throughput translates into lower production costs and faster delivery times, benefiting both manufacturers and customers.

2. Less Manpower Needed

Inkjet printing requires less manpower to operate compared to foil-wrapping lines. While a foil-wrapping line typically needs multiple operators for setup, adjustments, and monitoring, an inkjet printer only requires one person. The digital nature of inkjet printing automates many tasks, significantly reducing the need for human intervention.

This reduced reliance on labor lowers operational costs and minimizes the risk of human error, as the printer manages much of the process automatically.

3. Reduced Material Costs

One of the standout benefits of inkjet printing is the near-zero waste it produces. In foil wrapping, large rolls of foil must be cut to fit specific profile sizes, which always leads to leftover scraps. These scraps cannot be reused, contributing to material waste and adding unnecessary costs.

Inkjet printing eliminates this issue entirely. Designs are printed directly onto the profiles with "micron-precision," allowing manufacturers to use only the exact amount of UV primer, UV ink, and UV coating needed—no excess materials and no waste. This waste-free approach reduces raw material expenses and minimizes environmental impact, making inkjet printing a more economical and sustainable choice.

Additionally, the inks and coatings used in inkjet printing are generally less costly than the combined expenses of foils, glues, and primers needed for foil wrapping, further contributing to cost efficiency.

4. Energy Savings

Inkjet printing offers significant energy savings compared to foil wrapping. Traditional wrapping lines require profiles to be heated to activate the glue and ensure proper bonding, which consumes a substantial amount of energy.

Inkjet printing, by contrast, uses LED curing technology, which consumes far less energy. LED curing hardens the UV ink and coatings instantly without the need for high temperatures, making the process more energy-efficient. This reduced energy consumption not only lowers costs but also contributes again to a more sustainable production process.

5. No Waiting Time for Curing

An often-overlooked cost in foil wrapping is the storage time needed for the adhesive and primer to fully bond with the profile. After wrapping, profiles require up to 48 hours in a climate-controlled room to ensure that the glue and primer react and set correctly. This waiting period adds to production time and requires additional storage space, both of which increase costs.

With inkjet printing, there is no need for this extra curing time. Thanks to LED curing technology, profiles are ready for packing and shipping immediately after printing. This immediate readiness reduces storage needs, shortens the production cycle, and gets products to customers faster.

6. Warehouse Space

Another advantage of inkjet printing is the reduced need for warehouse space. In foil wrapping, manufacturers must keep a large inventory of foil rolls in various designs to quickly meet customer orders. This approach not only requires significant storage space but also ties up capital in the form of stocked materials that may not be used immediately, leading to increased costs.

In contrast, inkjet printing operates on a print-on-demand basis, where all decor files are stored digitally in the printer’s computer. There’s no need for physical inventory of designs, allowing manufacturers to free up valuable warehouse space and eliminate the costs associated with storing and managing large foil rolls. This efficient approach reduces overhead and ensures flexibility to quickly respond to customer needs.

Conclusion

As more manufacturers explore digital printing for PVC profiles, the advantages over traditional foil wrapping are becoming clear. For INTERNORM, one of Austria's leading innovators in window manufacturing, the shift to inkjet printing was driven by a commitment to sustainability.

However, in addition to environmental benefits, this transition also proved to be a smart financial move. The cost savings in production, labor, materials, energy, and storage make inkjet printing an increasingly wise choice for PVC profile decoration.

With the latest advancements in super-durable inks from TIGITAL Inks & Tattoo and the development of custom profile printers by Qres Technologies , inkjet printing has become a practical and sustainable option for the industry.

In upcoming articles, I’ll explore how this technology impacts the carbon footprint of manufacturers. I will also share more insights into the future of PVC profile decoration and how digital printing is changing the industry.