SHAPING THE FUTURE OF EMBELLISHMENT AND BRAILLE LABELLING

In a world where packaging must do more than simply contain products, the demand for tactile, embellished and accessible labelling is growing rapidly. A broad spectrum of packaging today needs to communicate quality, brand identity and, increasingly, meet legislative demands for accessibility and safety. These range from wine bottles and luxury brands on a store shelf, to pharmaceutical packs in a medicine cabinet. 

For converters and printers, this means finding solutions that can deliver high-impact embellishments, variable data and meet emerging regulatory requirements. At the same time, efficiency and sustainability need to be maintained. It is here that digital-inkjet printing is proving to be a powerful enabler of this transformation. 

Xaar’s latest evolution of its Versatex printbar is at the forefront of this change. It is a high-performance solution designed to bring digital capability to analogue print lines and converting machines. The printbar offers enhanced speed, precision and configurability. This is helping converters meet the growing demand for varnish, foil, braille and other tactile features. It also provides the unique capabilities of variable-data printing.

Embellishments such as varnish, foil and raised textures are strongly associated with premium packaging. These features not only enhance the visual appeal of goods, but also create a tactile experience that reinforces brand value. In sectors such as wine, spirits and luxury goods, embellishment of labels and packaging is often a key differentiator. However, the role of tactile, raised print is now expanding beyond aesthetics.

Accessibility is becoming a central concern in packaging design, driven by both consumer expectations and legislative change. In Spain, the government is reviewing regulation that will require braille labelling on a wide range of packaged consumer goods. This is in addition to an existing European Union (EU) directive, mandating braille on pharmaceutical packaging. It additionally reflects a broader shift towards more inclusive labelling of goods across Europe.

The proposed Spanish legislation – expected to be approved in late 2025 – will require braille on food items, hazardous products and other packaged goods. Information such as product names, allergen warnings and expiry dates may need to be included in braille. While the exact implementation timeline is still to be confirmed, the trajectory is clear. Businesses operating in European markets must prepare for a future where braille and other tactile features become mandatory.

“Embellishments such as varnish, foil and raised textures are strongly associated with premium packaging”

Digital printing offers a practical solution to ensure cost-effective, defined and scalable printing of variable-braille data. Xaar’s Versatex printbar has been developed to meet the demand for greater laydown of ink. The latest evolution offers a significant performance upgrade, doubling the headline speed in high-build print mode. It can now jet 100 microns at 50m/min, compared to 25m previously. This increase in speed is particularly valuable for applications, such as braille, where high laydown and precise dot formation are critical.

Powered by Xaar’s Nitrox printheads, the Versatex can handle fluids with viscosities of up to 1,000 centipoise (cP) at ambient temperature (around 100cP at jetting temperature). This allows for high-build printing and enables a wide range of effects. These include braille, cold-foil embellishment, white-flood fill, black variable data and digital personalisation. The new braille mode delivers faster and more defined tactile dots. In testing, the Xaar Versatex has achieved builds of 190–200 microns at 25m/min. 

“The Xaar Versatex stands out as a future-proof technology for high-performance coding”

For applications with lower build requirements – such as food packaging – the Xaar Versatex can already meet the necessary specifications. This makes it a highly versatile solution for converters looking to future-proof their operations. It is already being deployed across a range of global markets with installations in Portugal, Italy and the US. Thus, its capabilities are being demonstrated in live-production environments. 

For embellishments and innovative designs, the Versatex’s creativity print mode and Xaar’s unique high laydown technology, allow users to print between 15–100 microns at the same time. High-build gloss, standard or spot varnish and matte textures are all available to deliver high-quality, ornate tactile effects. These effects can increasingly be seen on premium labels in wine and spirits, cosmetics, perfumes and other high-end items. It allows designers to unlock a wealth of creative possibilities, combining textured and high-build print effects, varnishes and foils. The result is a striking impact of high-opacity whites and vibrant colours on labels and packaging.

With the ability to deliver high laydown black ink at speed, the Versatex printbar ensures exceptional optical density for crisp, scannable variable-data printing on challenging materials. These include coated papers, foils, plastics and cards. It makes the printbar a reliable alternative to traditional methods in packaging and security print. 

This precision and reliability make the Versatex printbar ideal for printing global trade item numbers (GTINs), serial numbers, batch codes and expiry dates. These are all essential for GS1 compliance as the retail industry moves toward mandatory 2D barcode implementation by 2027. Companies are beginning to adopt 2D codes on shipping cases for enhanced traceability and point-of-sale readiness. In these arenas, the Xaar Versatex stands out as a future-proof technology for high-performance coding.

One of the key strengths of the Versatex is its ease of integration. Now compatible with both left-to-right and right-to-left press directions, it is suitable for a wide range of finishing lines and press configurations. In addition, its modular design allows for seamless inline or offline integration, whether in new builds or retrofits.

The upgraded ink-delivery system and Meteor data path improve data handling and workflow flexibility, supporting high-volume and variable-data applications. A new on-press interface streamlines job set-up and image adjustments, making the system ideal for short runs and variable work. Minimal operator intervention is required, ensuring high uptime and consistent output.

“One of the key strengths of the Versatex printbar is its ease of integration”

With sustainability in mind, the innovative Versatex printbar – when compared to screen printing – offers shorter set-up times and a higher utilisation rate. This results in small-run jobs being completed faster. Furthermore, the ability to jet higher volumes and viscosities of fluids improves the print efficiency, reducing the need for multiple passes. In this way, faster speeds and a reduction in energy use and costs are achieved.

The Xaar Versatex printbar meets the needs of industrial converters and printers. The greater speed, precision and versatility of the new Versatex printbar is bringing the many benefits of digital to analogue presses and converting lines. Whether it is meeting demand for braille and embellishments or driving greater productivity and value in label production.

Indeed, as the print industry embraces a more tactile, inclusive and sustainable future, technologies, such as the Xaar Versatex printbar, are not just keeping pace, they are setting a new standard.