Paper:A Thousand Year Old Technology Still Under Development

Paper is Evolving

Paper accounts for the highest cost in book manufacturing.

Demand for writing papers continue to decline.

There is constant pressure to reduce costs.

The addition of inkjet is changing the rules on paper chemistry and

increasing paper costs.

The introduction of high speed aqueous inkjet printing required an entire new line of paper chemistry.

A New Printing Process

Although inkjet can run on traditional uncoated stock, treated and inkjet

coated stocks were developed for dye and pigment to enhance print and

color clarity by slowing colorant absorbed into the sheet.

“Water Based” Inks:• 65% - 95% water• Extremely thin- very low viscosity

New Aqueous Ink

Pigment Ink• Colorant is a “flake”• Chosen more for book printing• Provides better color fidelity on

uncoated sheetsDye Ink• Colorant is a “solution”• Provides better color fidelity on inkjet

coated sheets

Printing with traditional uncoated grades• Used for low image quality

requirements and to keep paper cost low, but…• Allows more ink to dive through

the sheet and lessens color and clarity• Darken or mutes colors• Image mottle in color blocks• Curl and cockle with lighter stocks• Heavy solids can cause finishing issues• Print will not resist water

New Ink + Old Paper

Dye -based Inks Pigment Inks

Water based Colorant dives into the sheet with the carrier fluid

Particles are more immobilized higher to sheet

surface. Still dives

Color Gamut Small, muted Larger than dye, muted

Show Through Has show through on light weight papers

Has show through on light weight papers

Stability Prone to fade UV resistant

Solid Black Density Low: 0.88- .90 Medium: .93-1.05

Solids Fill Flat color with little definition low contrast & definition

Dot Gain Control from 20% to100% Control from 65% to 100%

Ink & Paper Costs Stabilizing Stabilizing –new chemistry

Water Resistant NO- easily rewets, bleeds Pigment is generally water resistant. Will bleed through

Using Uncoated Paper

Aqueous inks need paper which: • Slows absorption• Dries quickly• Slows disruption of paper structure• Binds colorant on surface• Keeps more colorant on the surface• Provides image and color fidelity

New Ink + New Paper

Dye -based Inks Pigment Inks

Water based Colorant is more mobilized on the sheet surface

Colorant is more mobilized on the sheet surface

Color Gamut Large Larger than Dye

Show Through Has show through on light weight papers

Has show through on light weight papers

Stability Prone to fade UV resistant

Solid Black Density

Low: 0.1.03- 1.25; clean colors- paper dependent

Higher: 1.15-1.40; cleaner colors- paper dependent

Solids Fill Good density, and image definition Great density, and image definition

Dot Gain Control from 20% to100% Control from 65% to 100%

Paper Costs Stabilizing Stabilizing

Water fast Depends on paper treatment Pigment is general water fast

Using Treated Paper

Paper Differences

Uncoated - Least expensive, color dives into surface, spreads and dives unevenly. Lowest print quality. $ cost.

Inkjet Treated - Light coating on surface or in mixture, color sits higher to the surface, more spread and dive control. Higher print quality. $$ cost.

Inkjet Coated - Coating applied to paper surface, color sits upon surface, excellent spread control. Highest print quality. $$$ coat. Note some coated stocks do not dry well on some inkjet printers

Print Effect Aqueous Ink Paper

Ink Density Pigment inks better Pig-Pretreated/Treated

Show through Happens with pigment or dye Pig-Pretreated/Treated 60# and upDye-Treated 60# and up

Ink Bleed/Spread Happens with pigment or dye Pig-Pretreated/TreatedDye- Treated

Wicking Happens with pigment or dye Pig-Pretreated/TreatedDye- Treated

Paper Curl and Cockle Happens with pigment or dye Pretreated/Treated require less ink. Reduce ink coverage

Text and Color Gamut Both pigment and dye can provide with correct paper

Pig-Pretreated/TreatedDye- Treated

Light/Water fastness Pigment Ink Inline/Pretreated

Side to side color and image mottle

Dependent on paper Formation and inkjet coating/treatment consistency

Print Quality = Ink +Paper

If proper papers and weights are not chosen increased production costs and downtime can occur

Papers Affect Production

•Paper curl and cockle•Finishing jams and rough cuts•Score cracking•Paper dusting• Increased paper dust

• More steps and chemistry added to the process

• Increase density, color and image quality

• Expands color gamut

• Slows disruption of paper structure

• Helps reduce downstream finishing issues

New Paper= Price Increase

Uncoated147, 000 colors

@1200X

Treated229, 000 colors

@1200X

• As of this writing there are a multitude of paper mills in the USA as well as overseas manufacturing papers specially for aqueous dye and pigment inks

•Only certain mills offer treated PPI options

• Some mills require minimum order runs or truckload sizes

• As mills consolidate, inkjet paper grades may change names or chemistry. Always double check for consistency

•Adds more SKU’s to your floor

New Paper Availability

Color Gamut ComparisonSome digital printing machines/inks have wider color gamut than traditional litho printing.

Choose the process which best represents your book print, color and image quality needs!

Printing has different reproducible color space !

RGB Photo

Litho

Indigo Liquid Toner

Inkjet Dye

Inkjet Pigment

Inkjet UV

Process Color Differences

What it Means for You

Inkjet creates an efficiency for small runs

Papers which deliver better print quality are currently more $

Choose the process which best suits your density and print fidelity

requirements

Variable and personalization is a value added which can be

incorporated into publishing

Mary@SchillingInkjetConsulting.comwww.SchillingInkjetConsulting.com

5774 West 900 North, Fountaintown IN 46130317-947-8343@InkjetGenie

Providing inkjet machine, paper and print qualityconsulting before and after the inkjet purchase.