Digital printing is a significant industry, with the global digital packaging printing market projected to reach nearly $36 billion by 2026[1]. Consequently, many converters are considering investing in a digital printing press.
One of the key decisions when selecting the right press is choosing between two digital printing technologies: inkjet and electrophotography (toner).
As both options provide the recognised advantages of digital printing, this blog will explore each technology in detail, helping you make an informed decision about which press is most suitable for your business.
What is Digital Inkjet Printing?
Commercial digital inkjet printing, developed in the 1950s, operates similarly to a desktop inkjet printer but on a much larger scale. It uses a combination of software, hardware, and printing ink to reproduce digital images onto various substrates.
In the printing process, the artwork is broken down into a pattern of dots, which is then recreated by printhead nozzles that place ink droplets onto the substrate.
Colour digital inkjet printing presses contain multiple arrays of printheads and nozzles, allowing for seamless design printing by dispensing different coloured inks. These inks consist of colour pigments suspended in a carrier liquid, which are blended on the substrate to produce a wide range of colours and tones. The standard ink colours used are cyan, magenta, yellow, and black, with options to include additional colours such as orange, violet, and white.
The size of the ink droplets is crucial for creating fine details, including smooth gradients, microprint, and intricate Asian characters. Factors such as ink composition, viscosity, drop speed, and the substrate’s absorption properties influence ink laydown and colour blending.
For inkjet printing with UV inks, the inks are partially set in place by a pinning lamp during printing and then fully cured, resulting in a durable, high-quality finish.
What is Toner Printing?
Toner printing, also known as electrophotography, was first developed in 1938. This electrostatic printing technique, used in office photocopiers and laser printers, employs software, hardware, and either dry or liquid toner to reproduce a digital image on a drum, which is then transferred onto the substrate.
Liquid toner contains dyes or pigments and electrically charged particles encased in resin, suspended in an oil-based carrier liquid that evaporates during the fusing process. Dry toner, on the other hand, is a powder that behaves like a liquid due to its small particle size, although its particles are larger than those in liquid toner and require higher fusing temperatures.
Electrically charged toner particles are attracted to electrostatic fields, forming single-colour images. In liquid toner printing, multiple single-colour images are transferred onto a heated belt, where the layers are fused into a multi-colour image before being transferred to the substrate. In dry toner printing, the single-colour images are usually layered directly onto the substrate and fused using a heated roller.
The formulation of the toner, along with the contact printing and fusing process, means that the toner does not penetrate the substrate, maximising adhesion. However, this also means that toner labels often need a varnish or lamination to ensure durability.
Because of the limited bonding between the toner and substrate, not all materials are suitable for toner printing. Synthetic substrates, for example, require pre-treatment with a primer to ensure toner adhesion. OEM-approved materials, optimised for toner printing, are available but are often priced at a premium. Converters choosing digital printing with toner usually do so under a leasing arrangement with the manufacturer. In such models, each rotation of the imaging drums incurs a ‘click charge,’ a flat rate that covers maintenance and consumable costs.
Performance: Digital Inkjet Printing vs Digital Toner Printing
Both inkjet and toner printing technologies have their advantages and can deliver high print quality. In printing houses where both technologies are available, UV digital inkjet printing is often the preferred choice for converters. Several factors contribute to this preference:
Colour Consistency
Brand owners seek brand-compliant colour representation for their signature colours across all their labels.
Inkjet, a non-contact printing technology, is an excellent option for maintaining colour consistency. It can withstand fluctuating environmental factors, such as changes in temperature and humidity, without compromising print quality or consistency.
In contrast, toner printing is much more sensitive to variations in temperature and humidity, which can affect the reliability of the static charge and, consequently, impact print colour consistency.
Print Durability
Brands need labels that not only look appealing throughout their products’ lifecycle but also ensure compliance, particularly when featuring expiry dates, allergen information, or safety symbols.
The UV digital inkjet printing process provides consistent curing of the ink, with strong adhesion to a wide range of substrates used in the label market, resulting in a finish that offers long-term durability. Once cured, UV inkjet labels are resistant to scuffing and scratching, and they tolerate environmental factors such as heat, water, and chemicals. Additionally, they possess high lightfastness, ensuring colours remain vibrant and text stays legible throughout the product’s lifecycle.
This level of durability is achieved without the need for additional coatings, like varnish or lamination, which are typically required with toner printing. Converters with access to both technologies can save costs by choosing inkjet labels for more demanding applications.
Productivity
Productivity is a key factor converters consider when comparing digital label presses, and inkjet printing often comes out on top in terms of speed.
Both inkjet and toner printing systems available today can operate at high speeds; however, digital inkjet printing has the potential to run faster as it does not require physical contact with the substrate to create an image. Most inkjet presses can further boost printing speed by reducing the print resolution, and analysts predict that future advancements in printhead technology will allow for even higher speeds while maintaining high resolution[1].
In contrast, speed improvements are more challenging for toner printing, which relies on contact printing. Factors such as toner particle size, coverage, and the number of colours used influence the transfer speed and required fusing time. Increasing throughput typically requires multiple consecutive imaging engines, which increases the press’s footprint, as well as the initial investment and long-term running costs.
Textured Finishes
A UPM Raflatac neuromarketing study suggests that consumers are attracted to labels with tactile finishes and embellishments. Both inkjet and toner printing systems can enhance labels with textured effects to meet these consumer preferences.
Digital inkjet printing technology, equipped with high-opacity white ink, can create textured effects by printing a white pattern as a base layer, which is then pinned and printed on as usual. This process produces a textured finish without requiring a premium substrate.
While layering is also possible with toner printing, brand customers may be hesitant to pay the additional ‘click charges’ incurred when creating this layered effect.
Additionally, as a non-contact process, inkjet printing is well-suited for printing on uneven substrates, such as textured papers, making it a versatile option for achieving textured finishes.
Cleaning & Maintenance
Regular cleaning of printing components is essential for maintaining consistent print quality and preventing unwanted transfer.
Cleaning and maintaining an inkjet press can be straightforward due to built-in tools that automate tasks such as nozzle cleaning, capping, and printhead alignment and registration. Conversely, cleaning and recalibrating a toner press can be more time-consuming, often requiring a skilled operator.
According to Smithers’ The Future of Packaging to 2026 analysis, converters using toner printing technology generally experience lower uptime compared to those using inkjet technology, which impacts overall productivity and ROI.
Cost of Ownership
Cost of ownership is a crucial factor for converters, with consumables representing a significant portion of ongoing expenses.
Converters with access to both technologies often choose their toner press for producing labels with high coverage, as the ‘click charge’ remains constant regardless of toner usage, making toner a more cost-effective choice. For applications with average or low coverage, inkjet is usually preferred due to the lower ink costs for these tasks.
Smithers has noted a trend of decreasing total cost of ownership in digital inkjet printing, attributed to high productivity and lower ink costs, which are competitive compared to the ‘click charges’ commonly associated with toner printing.
Conclusion
As the global digital packaging printing market is set to approach $36 billion by 2026, converters are increasingly considering investments in digital printing presses. When choosing between inkjet and toner technologies, understanding the distinct advantages and considerations of each is essential.
Digital inkjet printing, developed from desktop printers to large-scale commercial applications, offers significant benefits, including high-speed production, exceptional colour consistency, and durable finishes. Its non-contact process and automated maintenance contribute to higher productivity and lower long-term costs. Additionally, the decreasing cost of ink and ongoing advancements in technology further enhance its cost-effectiveness.
On the other hand, toner printing, with its established history and reliable performance, remains a viable option, particularly for high-coverage labels where fixed ‘click charges’ make it economical. However, it often requires more time-consuming maintenance and may not be as versatile on varied substrates.
Ultimately, the choice between inkjet and toner printing should align with your specific needs for colour consistency, print durability, productivity, and cost of ownership. Both technologies offer high-quality results, but inkjet printing generally provides greater flexibility and cost efficiency, making it a compelling choice for modern digital packaging applications.
[1] Smithers. The Future of Digital Print for Packaging to 2026. 2021
