Technology

BREAKING THE RELIANCE OF AQUEOUS INKJET ON SPECIALIST SUBSTRATES

Company
Nazdar
Dr Saminu Magami, R&D Scientist, Nazdar
Author
Dr Saminu Magami
Further Information
Published
4th Sep 2025
Dr Saminu Magami of Nazdar, explains the fluid demands that rule inkjet printing on porous versus non-porous media, as well as new technology that is redefining possibilities

A longstanding challenge in single-pass industrial printing has been the reliance on specialised media to make aqueous inkjet inks perform reliably. This reliance is also true with primers or surface coatings. The constraint has limited flexibility and added complexity to production. Nazdar, however, is paving a different path. Breakthrough technologies are unlocking new possibilities. High-speed, high-quality aqueous inkjet printing is now achievable, without relying on conventional crutches across various media types.

Dr Saminu Magami, R&D Scientist, Nazdar
Dr Saminu Magami, R&D Scientist, Nazdar
INKJET PRINTING – POROUS & NON-POROUS

The contrasting fluid requirements of inkjet printing on porous media versus non-porous media comes with limits per the different surface types. Nazdar’s R&D team has challenged these limitations, by leveraging advanced formulation strategies and expanding the viscosity range of its inks. As a result, Nazdar is able to deliver breakthrough solutions across a wide variety of substrates, including both porous and non-porous materials. This innovative approach opens new possibilities for industrial-inkjet printing. It reduces the need for costly pretreatment processes while maintaining high-quality output.

Select inks from Nazdar’s HighV Aqua Series can be applied in a single-pass process directly onto both porous and non-porous substrates. There is no need to use primers or surface coatings. High V Aqua formulations improve versatility and performance, even under challenging, untreated conditions.

“Ink penetration into porous media can be wasteful”

Print sample on PET (a non-porous substrate), produced using Nazdar’s HighVAquaFlex Black ink – demonstrating excellent adhesion and image clarity without the need for surface treatment
Print sample on PET (a non-porous substrate), produced using Nazdar’s HighVAquaFlex Black ink – demonstrating excellent adhesion and image clarity without the need for surface treatment
UNDERSTANDING EACH MEDIA TYPE

The opposing properties of porous and non-porous media reshape how inkjet inks must be formulated. This is because every surface demands a different chemistry and the stakes are high when precision meets speed. It significantly influences the requirements for each substrates’ inkjet-ink formulation and printing. Primarily, this is due to how the inks interact with different surface types. These interactions – such as wetting, spreading, absorption, interlocking and adhesion – are governed by a range of factors. They include surface energy, porosity, ink receptivity and whether or not the substrate has been treated, primed or coated.

“Surface variables dramatically impact ink performance”

On porous substrates, such as corrugated board, the ink tends to be partially absorbed into the material. While this natural absorption can reduce the need for intensive drying, it also introduces challenges. Without careful control, it may lead to feathering, diminished colour vibrancy or a loss of image sharpness. In contrast, non-porous materials, such as plastic films (PET, OPP, PE, etc) do not absorb the ink. As a result, they demand more deliberate drying strategies and often require the use of adhesion promoters. These additives enhance ink wetting and bonding, ensuring the ink remains fixed to the surface and delivers consistent, high-quality results.

Print sample on white corrugated board (a porous substrate), created with Nazdar’s HighVAquaCoro Black ink – showcasing strong absorption control and vibrant image quality on untreated media
Print sample on white corrugated board (a porous substrate), created with Nazdar’s HighVAquaCoro Black ink – showcasing strong absorption control and vibrant image quality on untreated media
FORMULATING FUNCTIONAL FLUIDS

To achieve optimal print performance, the chemical and physical properties of the ink must be precisely matched to the characteristics of the target substrate. The main challenge with porous materials is excessive ink absorption. Therefore, these formulations must exhibit carefully controlled rheological behaviour to prevent unnecessary penetration. This requires a balanced composition of solvents, binders and functional additives that regulate flow and absorption to ensure sharp image definition and colour integrity.

Conversely, non-porous substrates do not absorb ink. This makes adhesion difficult – especially when high print quality is a must. Achieving durable adhesion relies on a delicate balance between the ink’s wetting properties and the surface energy of the substrate. In such cases, the formulation must be engineered to promote effective surface interaction. This enables strong anchoring, without compromising print quality or durability.

Print samples on brown corrugated board (porous substrate), printed using Nazdar’s HighVAquaCoro Black and Magenta inks. These examples highlight the inks’ ability to maintain colour strength and image definition on untreated, absorbent surfaces – demonstrating controlled ink penetration and consistent visual impact
Print samples on brown corrugated board (porous substrate), printed using Nazdar’s HighVAquaCoro Black and Magenta inks. These examples highlight the inks’ ability to maintain colour strength and image definition on untreated, absorbent surfaces – demonstrating controlled ink penetration and consistent visual impact
NEW INNOVATIONS FOR CORRUGATED BOARD

Successful high-viscosity inks have brought new possibilities to printing on this porous surface. Generally, corrugated board presents a unique challenge as a print medium, due to its inherently variable nature. Factors such as surface unevenness, the type and characteristics of the liner, recycled content, the presence or absence of pre-coating and variations in primer finishes all contribute to its complexity. Surface variables dramatically impact ink performance – affecting absorption, wetting, dot gain and ultimately, colour consistency and reproduction.

“Nazdar’s innovations are reshaping aqueous inkjet printing”

To navigate these challenges, precise control over ink formulation is essential. Equally important are accurate droplet placement and carefully managed drying dynamics. Together, these elements form the foundation of a robust digital-printing process capable of delivering consistent, high-quality results.

CHALLENGES – INK PENETRATION IN POROUS MEDIA

Ink penetration into porous media can be wasteful for several reasons, making it essential to strike the right balance. Excessive ink absorption into the corrugated board during digital printing can lead to several critical issues – both economic and qualitative. When the ink penetrates too deeply into the substrate, it wastes material, increases production cost and fails to enhance the print quality. Instead, it can cause the print image to appear dull or blurred. This is because the ink spreads beyond the intended print area, reducing image sharpness and vibrancy.

Moreover, if the ink formulation is not carefully controlled, this deep absorption can hinder drying efficiency. In such cases, more energy or extended drying times may be required to fully cure the ink. This further impacts production throughput and cost-effectiveness. In essence, managing the ink penetration is vital to overcoming these challenges. As well as achieving high-quality print results, it is essential to maintain operational efficiency and cost-control in corrugated-printing applications.

Print samples on brown corrugated board (porous substrate), produced using Nazdar’s HighVAquaCoro Cyan and Black inks. These examples illustrate the inks’ ability to deliver strong colour performance and image clarity on untreated, absorbent surfaces, despite the natural variability of the board
Print samples on brown corrugated board (porous substrate), produced using Nazdar’s HighVAquaCoro Cyan and Black inks. These examples illustrate the inks’ ability to deliver strong colour performance and image clarity on untreated, absorbent surfaces, despite the natural variability of the board
OPTIMISING INK FOR TOUGH MEDIA

Whether dealing with porous or non-porous media, an increase in ink density is not always the right approach. ‘Balancing the book’ becomes critical. Nazdar’s high-viscosity fluids must go far beyond high(er) pigment loading to be functional and economical. 

Increasing ink density, by adding more pigment, might seem like a simple way to achieve vibrant colours on porous corrugated media. However, it often leads to diminishing returns and unexpected issues. While it might initially enhance colour strength or compensate for ink absorption, excessive pigment loading can disrupt fluid stability, complicate rheology and even cause issues with printhead performance.

When it comes to the ink application, over-saturating the substrate with ink can result in bleeding, extended drying times and, in some cases, structural weakening of the board itself. Moreover, higher ink usage drives up production costs without necessarily delivering better visual outcomes.

Achieving optimal print quality on corrugated media therefore requires a balanced approach. Success comes through extensive fine tuning, ink formulation, controlling ink lay down, managing colour profiles and understanding how the ink interacts with the substrate. In this context, achieving high-quality, affordable and sustainable prints depends on precision 
and not on using more ink. Navigating that balance requires an expertise in formulation and detail. It is exactly this level of technical sophistication that is unlocking bold new possibilities with Nazdar’s high-viscosity Inks.

CONCLUSION

The technology of aqueous inkjet in single-pass, industrial printing has been reliant on specialist substrates since its inception. Navigating ink formulations for porous and non-porous media often requires a reliance on a number of factors. These include costly pretreatment processes, primers and surface coatings to achieve acceptable performance. However, Nazdar’s innovations are reshaping aqueous inkjet printing, breaking the boundaries of substrate limitations. From porous corrugated board to smooth, non-porous films, high-viscosity fluids demonstrate that precision – rather than excess – is key to quality, consistency and efficiency. By mastering formulation and optimising fluid behaviour, this new technology opens doors for sustainable, high-speed printing, without the need for primers or coatings. Once thought out of reach, success lies not only in solving technical challenges, but also in redefining the abilities of aqueous inkjet across substrates.