DoraniX specializes in direct to product printing, specifically on cut sheets, pouches, cards, bags, etc. DoraniX has most recently developed the ThermaPrint 64 to fill the void in singles thermal transfer printing. Additionally, DoraniX offers a line of integrated label applicator systems to accommodate an even wider range of products including cartons, coffee bags, etc.
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Tyvek has been used for more than 40 years in a vast variety of roles. It has been made into clothes, used to protect building sites, and is the most commonly used material in health-care packaging.
In most of these roles, the material needs to be printed. The techniques used to do this vary, depending on the scale and complexity of the printing required. In all cases, however, care must be taken not to damage the substrate – for whilst Tyvek is incredibly strong in some ways, it is also sensitive to heat and certain solvents.
For large-scale printing, Flexographic and Lithographic techniques are often used to print on Tyvek. Whilst these processes work well for Tyvek sheeting, producing and printing packaging with Tyvek requires a different approach. Inkjet inks do not, generally, dry quickly enough to be of use for batch production, and are difficult to print at a high enough resolution to meet the requirements of medical packaging.
Thermal techniques have, therefore, become standard for the batch production of Tyvek packaging and labels.
Using this technique, even large orders can be produced relatively quickly, and labels can be printed at high quality. In addition, many modern thermal Tyvek printers are able to automatically print unique content onto each label or package, greatly improving efficiency.
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Tyvek is a registered trademark of Du Pont, who first discovered the material in 1955. It was trademarked in 1965, and released for general use two years later. Since then is has become ubiquitous in many industries, and is the go-to material for sterile packaging.
Though superficially similar to paper, Tyvek is completely synthetic. It consists of spunbound Olefin fibers, each between 0.5-10 µm in width, which are bonded together using heat and pressure.
Tyvek has many useful properties. It is extremely lightweight, and yet also tough. It resists tearing very well, and yet can be cut easily with scissors. It is not flammable, has good opacity, and a neutral PH level. Perhaps most usefully, it is breathable, being permeable to water vapor but not liquid water.
Tyvek is used in a vast variety of roles, including HAZMAT suits and wristbands for festivals, and is a familiar sight protecting buildings for adverse weather.
One of its most common uses, though, is in medical packaging. Critically, Tyvek can withstand the conditions used to sterilize medical equipment, meaning that Tyvek packaging is able to keep this equipment sterile for long periods.
In most roles, Tyvek needs to be printed. It generally makes an excellent substrate, and can be printed in a variety of ways, though care must be taken not to damage the material whilst working with it.
For the printing of large-scale designs, such as when a company’s logo needs to be printed onto Tyvek sheeting, Flexographic printing is most often used. Care must be taken, whilst doing this kind of printing, to optimize the tension of the substrate, keep temperatures within recommended bounds, and use the correct levels of pressure.
Our focus here, however, is on printing Tyvek for packaging, and the techniques used to do this are slightly different. Typically, batch production of packaging or labels requires that each item be uniquely printed, for instance with a unique bar-code. In addition, printing information onto small labels necessitates good print quality for the label to be read easily, especially if the package is destined for medical use.
Unfortunately, Inkjet methods are not suitable for printing on Tyvek. It is possible, with the correct set-up, to obtain reasonably good quality images. However, the non-permeability of Tyvek means that even with the perfect system, Inkjet ink is slow to dry on the substrate. This makes these methods unsuitable for large-scale batch production of labels.
It is difficult to find a reliable thermal printer that can work with Tyvek, but overall this is the optimum solution for batch production of packaging with the material.
These printers can produce labels and packaging quickly, and have good enough resolution for medical environments. In addition, many systems can now automatically generate unique bar-codes and other information for each package.
Choosing a Tyvek printer for packaging depends on your own requirements, and the types of orders that you are processing.
However, no matter the type of printing you are doing, some things should always be taken into account when choosing a Tyvek printer:
One of the most important considerations is speed. Print orders for the health-care sector are often of very high volume, and so a printing speed of at least 5 inches/second is a must. In addition, some Tyvek printers now have a slew capability, allowing them to quickly skip over non-printed sections of the substrate, greatly improving overall speed.
Print quality should also be a major consideration.
Often, packaging and labels require that very small writing be reproduced precisely, and this is of special concern in the health-care sector. Nowadays, the best thermal Tyvek printers are able to print at up to 300 DPI, which is more than sufficient for these purposes.
If you are dealing with extremely large orders, an automated and motorized sorting module is also extremely useful. In many cases, an order for Tyvek packaging will contain several varying types or sizes of package, and a motorized sorter means that each type will be automatically stacked in the correct pile.
Another consideration should be the adaptability of the printer. A good Tyvek printer will be able to deal with a wide range of thicknesses, offer several different fonts, and even cut packaging into a variety of formats and shapes.
The cost of consumables should also be considered. Whilst most Tyvek printers use thermal printing techniques, some now come with advanced features that significantly improve efficiency, meaning that consumables will last longer.
Last but not least, of course, the ruggedness of the printer should be assessed. Tyvek printers, like a lot of industrial printers, often need to work reliably in quite difficult environments, and the printer should be able to deal with heat, dust, and other complications.