INKJET FOR METAL PACKAGING – THE JOURNEY SO FAR

While some print sectors transitioned to digital early and rapidly, others have lagged much further behind. There is no doubt that metal packaging sits very firmly in the latter category. It is still, overwhelmingly, an analogue world. 

There are many reasons for this. Developing any world-class, inkjet-jettable inks is challenging enough. However, designing inks for low-viscosity, high-resolution printheads, with the essential properties for metal packaging, takes that challenge to another level. Developing the necessary combination of flexibility and scratch-resistance to withstand the rigours of the can-forming process – as well as packing and transportation – requires the overcoming of challenge, upon challenge, upon challenge.

In 2020, Fujifilm introduced its first ink for metal packaging onto the market

Adding the challenges of printing at speed and of being food-safe compliant (essential for such a large proportion of metal packaging printing), it is easy to see why this is a sector still dominated by traditional print technologies. 

However, even in metal packaging, this is changing. As ever, Fujifilm is at the forefront of driving that change.

Fujifilm is a global technology company investing millions in R&D annually. The company was one of the earliest pioneers of inkjet technology for the sign and display market in the late 1990s. It also has a heritage in ink design and manufacturing that goes back decades. As a result, Fujifilm is uniquely placed to tackle the complex challenges of developing inkjet inks for metal packaging. 

Developing close working relationships with the best raw material suppliers on the one hand, and expert OEM partners on the other, it has been a step-by-step process. Huge progress has been made, especially since the start of the current decade. In 2020, Fujifilm introduced its first ink for metal packaging onto the market. It was CMYK-only to start with and, though white inks and varnish had to be laid down separately, it still opened up a world of creative possibilities for ultra-short runs, promotional cans or production of ultra-high quality sales samples.

From flawless colour-matching accuracy in paint tester pots, to personalised corporate gifts, to retail promotional displays, the technology quickly began to prove its potential.

Fujifilm worked hand-in-hand with customers, to help them understand the possibilities of inkjet and how to achieve them – from the selection of base-coat materials to identifying the optimal conditions for every application.

Fujifilm is uniquely placed to tackle the complex challenges of developing inkjet inks for metal packaging

The next challenge was food-safety compliance. A massive proportion of metal packaging is for food products, meaning that indirect food contact (IDFC) compliance is really a minimum requirement for widespread pick-up. In 2021, Fujifilm launched its first IDFC ink – which continues to comply with Nestle List and Swiss Ordinance – and has been used in multiple real commercial applications. But food safety regulations are ever-changing. Fujifilm’s dedicated regulatory team is always looking ahead to anticipate significant new legislation, such as the German Ink Ordinance, expected to come into effect on 1 January, 2026. The company ensures that stringent health and safety requirements are met, and that businesses can plan ahead, with confidence, in a rapidly changing regulatory environment.

Development has now moved beyond CMYK, with OEM trials well underway for a new low-viscosity white ink and a UV-jettable varnish. This will remove the need for separate litho processes for preparation and finishing, making the whole process simpler and faster. It will also broaden the range of applications that can be produced. Fujifilm’s low-viscosity white ink enables the flexibility to deliver both high coverage flood areas and fine detail for text. This combination is very difficult to achieve with standard high-viscosity digital white inks. There is also a substantial energy saving benefit to the introduction of the UV-jettable varnish. This is because the energy use and cost is significantly lower than when applying a conventional, thermally cured varnish. Digital varnishes also open up the possibility of introducing a range of eye-catching special effects, which would be difficult to replicate using analogue technology.

Digital varnishes also open up the possibility of introducing a range of eye-catching special effects

The final challenge to make inkjet a true alternative to offset, is speed. For all the benefits of flexibility and creativity on offer with multi-pass inkjet – such as ink layering for textured finishes, personalisation and customisation – it can only ever be truly viable over very short runs. Single-pass inkjet, on the other hand, combines the speed of litho printing with all the benefits of digital, making it a truly viable alternative to traditional printing processes. 

It is inks for single-pass inkjet that will move the digital-print transformation in metal packaging from baby steps to a sprint. 

After decades of inkjet-ink development and years of adapting and perfecting inkjet inks for metal packaging, Fujifilm is proud to be bringing to market an ink solution for single-pass inkjet, designed specifically for the rigorous requirements of metal decoration. Scratch-resistant, flexible and IDFC compliant, this single-pass ink is in advanced stage trials with OEM partners and can be adapted to meet the varied requirements of metal packaging printers across the industry. A fully IDFC, single-pass, inkjet ink for metal decoration is now very close to being a commercial reality. Real digital transformation in metal packaging just got a step closer.

To learn more about Fujifilm’s single-pass, inkjet offering or to request a free sample pack, contact oliver.mills@fujfilm.com