Roll-to-Roll Printing Technologies

Is today's large-format printing scenario lively and extremely interesting? Of course, it is.

The availability of various technologies, which can satisfy any customer's request in almost every segment, has reached such a high level that, when planning to purchase a new device, we paradoxically fight with two feelings. The first is the joy of choosing the solution that best fits our needs; the second is the hesitation in finding the suitable device that such abundance could instil.

Regardless, it's crucial how our company can respond flexibly to the demands of a sometimes capricious market without disrupting its production processes.?

An interesting point of note from the?FESPA Census report , which is also echoed in other industry reports, is how the ability to adapt to the market in terms of flexibility, speed, and quality has become even more pressing and key for any printing company.

Between the various printing technologies available, this article will focus on roll-to-roll (R2R) eco-solvent, UV, and resin/latex printing technologies regarding usage and potential applications to help make a more conscious choice. Let's go!

Eco-solvent R2R

Large-format printing owes much to this technology, especially since the shift to eco-solvent inks in?more entry-level devices ?has allowed many businesses to enter the digital printing domain and utilise a stable, secure, and highly adaptable technology (which was the birth of digital sign-making).

FESPA Census research shows eco-solvent is second in global printing companies' acquisition plans, testifying to the longevity and appreciation of such R2R technology.?

Pure solvents initially had significant environmental impacts. The industry's adoption of eco-solvent inks has reduced volatile organic compounds typically associated with solvents and safer use, and in parallel, there has been an incredible development of printable substrates for any graphic application.?

They have even enabled environmental certifications such as GreenGuard for more sensitive environments. I suggest reading?this article ?for a more in-depth analysis of eco-solvent inks and debunking some misleading information.

Indeed, eco-solvents are a mature technology with forecasted growth from?4% ?to?5.5% ?by 2030, mainly due to the diffusion amongst PSPs.

Today, manufacturers focus primarily on versatility in printable graphic applications, quality of printing results, ease of use, productivity (meaning that it should quickly adapt to the company's printing volume and related peaks) and compatibility with eco-friendly materials.

Who should consider an R2R eco-solvent printer?

Eco-solvent is ideal for starting users who require versatility and ease of management or, if they already own such technology, need a technological update due to lease expiration, rental termination, or technological obsolescence.?

The availability of inks such as orange, green , and white for an extensive reproducible gamut should also be considered. The print and cut devices could also be suitable for PSPs owning water-based or latex printers to expand the

As said above,?eco-solvent devices ?are noted for their versatility and, thus, for their variety of applications. It excels in?vehicle graphics , outdoor communication (one of the most requested graphic applications), apparel and?stickers .?WLM Design , for example, uses eco-solvent printing for various usages.?

UV Technology R2R

Gaining market share for?UV technology ?was just a matter of time. As confirmation, growth trends project UV technology at?9.5% ?until 2030.

According to an analysis from?Napco ?(US), 39% of the interviewees had already adopted a?UV R2R. At the same time, research from?WidhtWise ?UK says that 23% of the persons interviewed already work with an R2R UV device, a figure similar to that declared in the FESPA 2024 Census report (22%—Global).?

The main reasons are that UV instant drying renders prints immediately usable (unlike eco-solvent, which requires at least 6 hours to dry thoroughly for lamination or installation), it can print on many materials without particular issues, and adding textured or relief effects makes it a noticeable advantage.

It also allows adding?red or orange inks ?to enhance brightness and chromatic yield, white ink for printing on clear, transparent, or dark surfaces, and combining cutting with printing.?

An exemplary use of chromatic rendering is the UV print/cut by?Royal Enfield.

Note that UV inks also have GreenGuard certifications for indoor use, further expanding the range of applications.

Who should consider a UV R2R printer?

UV excels in printing on challenging materials and offers impressive colour yield. It is ideal for creating retail outlet signs and displays, backlit displays, relief effect decorations, decals, and customised packaging (see?here ?for a more in-depth explanation).

Some UV printing applications overlap with eco-solvent printing (like sticker printing), but this is seen as beneficial, considering a more prominent company's productivity power when it has both technologies.

So UV can fit those who are starting with the intent to produce specific applications as described above or for mature printers who want to expand their technological portfolio to cover any needs and quickly respond to customer requests.

Resin/Latex R2R

The printing technology sector has seen remarkable interest in the advancement of?resin/latex-based R2R printing solutions . These technologies are particularly acclaimed for their low environmental impact and heightened emission safety, making them suitable for indoor use. Such characteristics are leading to?cautious ?yet promising growth expectations on a global scale.

Ink formulations for these technologies, comprising water-based mediums enriched with resin and pigment, are tailored for compatibility with sensitive environments such as?hospitals ?or public spaces. If you want to know more, this?article ?gives an in-depth description of resin/latex technology.

Initially positioned as alternatives to established printing methods, resin/latex-based solutions are now being adopted not as substitutes but as complementary offerings, expanding the scope of graphic application possibilities.?

Current advancements in resin/latex technologies have unlocked new potential in?print texture and uniqueness , catering effectively to interior decoration needs and point-of-sale environments.

Who should consider resin/latex?

This printing method is ideal for those engaged in extensive interior applications, wall coverings,?wallpapers , or businesses requiring prompt post-printing. Resin/latex can also serve graphic applications like?vehicle wrapping , fabric, and signage.

It is mainly geared towards experienced printing professionals looking to expand their markets into interior design and decoration, collaborating with architects and designers on retail or event projects.

Employing these technologies for visual communication necessitates proper planning to ensure a seamless production flow and maximise efficiency during the preheating and material loading phases.

Conclusion

As it becomes clear, selecting the?most suitable printing technology ?necessitates analysing what you wish to produce, how you intend to do it, and your company's plans.?

Even when they overlap in some instances, technologies have application methodologies that are more appropriate in specific contexts. So, they should be considered complementary, depending on the company's business plan.

When in-house, these R2R technologies undoubtedly allow PSPs to offer versatile and customised printing solutions, broaden their market reach, and meet various customer requests.

Some extra suggestions.

Sometimes, investing in the technology you already have may be more cost-effective, especially if you need to increase productivity rather than enter new markets.

However, if the goal is to embrace new customers and markets, consider how the new technology will integrate with your company's workflow and ensure it keeps its revenue-generating applications intact.

Where feasible, it's best to stay within the brands you already use, maximising user experience and using existing RIP software. This avoids starting the learning process anew while reducing the switch costs.

The final advice is always to sit down with your trusted supplier, evaluate the options, test the technologies, and understand if and how they can help grow your business.?