EFFICIENCY THROUGH STANDARDISATION – STARTING WITH DIGITAL PRINTING

Digital printing offers significant advantages over traditional methods, such as faster turnaround times, lower production costs and cost-effective customisation. However, the path to efficient and reliable digital printing has its challenges. Through extensive testing, workflow optimisation and the integration of advanced software tools, Interprint was able to achieve both efficiency and precision in its digital-printing operations. Central to this transformation was the role of ColorGATE software, which played a crucial part in stabilising the process and ensuring the consistency needed for high-quality results.

“Interprint recognised the importance of optimising the ‘make-ready’ time”

Interprint is a global leader in the printing of decorative surfaces and is part of the Toppan Group, headquartered in Tokyo, Japan. With over 50,000 employees and an annual turnover of approximately €12 billion, the company’s expertise spans across printing, design and innovation.

ColorGATE is a leading provider of software solutions for digital printing. With more than 19,000 installations worldwide and over 2,000 supported devices, ColorGATE helps businesses achieve high-quality, efficient and profitable digital printing.

Interprint was among the early pioneers adopting digital printing within the décor industry. The company’s forward-thinking approach allowed it to experiment with and refine digital-printing processes before they became widespread. However, transitioning from analogue to digital printing is not simply a matter of transferring existing processes to new technology. Interprint had to rethink not only its workflows, but also its entire approach to production. Additionally, investments in machines, substrates, inks and more, were hard to justify when results were inconsistent and unpredictable. 

One key takeaway from this experience was the importance of involving all partners – device manufacturers, ink suppliers, substrate providers, software developers – early in the process.

ColorGATE, with its deep expertise in digital-printing systems and processes, became a central partner in overcoming these challenges. ColorGATE’s knowledge in substrates, inks and décor production helped Interprint to navigate the complexities of digital printing while minimising trial and error.

The digital-print process typically follows a standardised workflow – design creation, print data generation, pre-processing, printing, post-processing and finally, the product. In theory, repeating this workflow with the same settings should yield identical results. In practice, however, slight drifts, often in the hardware components, can cause variations in the final output. These variations may seem insignificant at first, but can accumulate noticeable differences in colour or print quality.

To achieve efficient digital printing, Interprint recognised the importance of optimising the ‘make-ready’ time. This is the period required to adjust the printing system before beginning production. Whether in digital or analogue printing, numerous variables can influence print quality, including ink viscosity, substrate stability, climatic conditions and the print system’s density reproduction. Every time an adjustment is made, at least one of these factors changes.

In analogue printing, these fluctuations are somewhat accepted. Operators often adjust parameters such as ink viscosity or squeegee angles to compensate. In digital printing, however, these variations can result in unpredictable and inconsistent output. To tackle this, Interprint and ColorGATE focused on stabilising the variables, enabling consistent results across print jobs.

The solution was simple yet profound – standardisation.

Standardisation involves measuring and visualising the process at each step, to identify where variations occur. By using ColorGATE’s suite of tools, Interprint was able to standardise its digital-printing processes and minimise variations. One such tool is the Quality Assurance Module, which ensures colour accuracy by setting deviation alerts and customisable DeltaE limits.

Another crucial tool is Media Device Synchronization. This allows for consistent, high-quality prints across multiple devices and locations, ensuring that the output is uniform on different printers or facilities. Additionally, ColorGATE’s Fingerprint technology enables the creation of a digital master file that captures all production steps. This file serves as the reference for reprints, ensuring the same results are achieved each time.

“Interprint and ColorGATE focused on stabilising the variables”

For managing colour drifts, the Color Correction Loop automatically adjusts colours during reprints. When using the Fingerprint system, shifts in colour are quickly corrected. Finally, ColorGATE’s 3xP2P approach – matching production to production, printer to printer and plant to plant – creates consistency across different locations and printers.

By establishing standards for its digital-printing process, Interprint was able to stabilise variables and achieve predictable, high-quality results. This process is not limited to a single location but used globally. The approach ensures that print production is efficient and results match the high quality expected.

An important component of Interprint’s success is its in-house proofing capabilities. By using the same inks, papers, primers and ColorGATE software, the company is able to reliably proof prints across various locations worldwide. This reduces transport costs and contributes to sustainability efforts by enabling production and proofing at different sites. Furthermore, the establishment of standardised training, installation and maintenance procedures ensures that these efficiencies are consistently implemented across the business’s global network.

Looking ahead, the trend in digital printing is clear – automation will take standardisation to the next level. Automation can help remove subjectivity and further improve the consistency of outputs. As more tools become integrated into automated workflows – for example, via ColorGATE’s REST API – even shorter make-ready times and more streamlined production processes are possible.

Starting with digital printing may seem like a daunting task, but with the right partners and a clear focus on standardisation, the journey can be efficient and profitable. For Interprint, the key was understanding the challenges of digital printing, establishing and training know-how and involving the right partners early on. With ColorGATE’s suite of tools, Interprint was able to measure and visualise process variations, stabilise print results and optimise workflows. The result is a more efficient, consistent and cost-effective digital-printing operation.

As the digital-printing landscape continues to evolve, embracing standardisation and automation will be crucial for companies looking to stay competitive. The combination of smart workflows, reliable tools and consistent processes, is the future of high-quality digital printing.