The Décor industry is diverse and includes the decoration of wood laminates, a sector of focus for Xaar. The Décor sector also covers glass, vinyl flooring and wallpaper.  All sub-sectors are at the early stages of an exciting transition from using traditional analogue printing methods to digital inkjet technology.
Within the laminates sector, Xaar printheads are used to print patterns or images directly onto laminate boards or paper used to produce flooring, furniture and panels. Laminated wood is big business with approximately 7.5 billion square metres produced annually. In such a thriving industry, Xaar printheads enable manufacturers to deliver a far broader range of design variations than traditional print processes can manage. As digital print facilitates short run, on-demand production, Xaar printheads enable rapid design introduction and dramatically reduce inventories. 

Why digital?

Mass customisation

  • ​With no limit to run length, digital printing enables cost-effective production even for small quantities. This opens up the opportunity for infinite design variations and the capability of producing customised or one-off products
  • Image size and pattern lengths are not constrained by the limited repeat distance of analogue plates or rolls, which means that pattern repeats in a floor design, for example, can be eliminated.

Reduced cost

  • ​Digital printing can supply exactly what is needed, when it is needed, so there is no need to manufacture excess volume due to minimum batch sizes. This eliminates the requirement to hold large volumes of stock due to minimum run lengths
  • Exact order quantities also help to minimise the cost of obsolete stock due to design change
  • The extra cost of set-up time and material incurred with analogue print processes are removed which, with décor paper, can be thousands of square metres.​

Fast time to market

  • ​Digital printing offers rapid job turnaround.  As soon as a design is approved it can be sent straight to print. There is no need to prepare plates or engrave cylinders prior to printing
  • Designs can be changed on the fly, at the touch of a button, so there is no time lost between jobs
  • Digital printing can significantly reduce production lead times by moving the print operation from a dedicated site to the local conversion product or unit. For example, digitally printing a design directly onto a finished wood laminate product, rather than ordering décor paper on a long lead time from a specialist gravure printer.​​

Why inkjet?

Superior quality finish

  • ​Digital inkjet printing delivers a high quality, fine detail finish, making it easy to create designs that are faithful to the original, and patterns that are virtually indistinguishable from wood and other materials
  • As a non-contact printing process, digital inkjet can tolerate variations in substrate thickness. This ensures total consistency of print finish on substrates such as wood laminates and other décor materials which vary in thickness​

High adaptability

  • ​Inkjet is easily scalable, so that print widths can be varied to meet the needs of different applications: from 50 mm furniture edge banding to 2100 mm wide décor paper
  • Inkjet has the capability of printing onto a wide range of substrate thicknesses, from a 60 gsm paper through to 100 mm, glass panels and beyond. In addition it can print onto ridged surfaces or grooves, such as panelled doors or furniture, which gives it great versatility in an unlimited choice of print applications.​


Why Xaar?

The printhead of choice for the laminates sector today is the Xaar 2001+.

Ultimate design versatility
The Xaar 2001+ family of printheads is ideal for printing an extensive range of laminate designs and patterns. Printers enabled with the Xaar 2001+ can respond more quickly and cost effectively to design changes.

  • Jets one colour at 720 dpi or two colours at 360 dpi each, enabling ink configuration changes to respond to design trends
  • Available in 3 drop sizes: the GS6C (6 pL) prints very fine details; the GS12C (12 pL) balances fine details and high laydown; the GS40C (40 pL) jets the highest laydown for special effects
  • 2000 Optimised Geometry nozzles deliver high productivity with a broad range of oil-based inks.
Production flexibility

The Xaar 2001+ family delivers market-leading print quality, high productivity and high ink laydown to create laminates that are differentiated from the competition.

  • Market-leading print quality, with up to 720 dpi and 8 grey levels, means that laminate manufacturers can produce a wide range of designs.
  • Fast line speed of 50 m/min (ink laydown up to 39 g/m2*) enables high production throughput and a fast return on investment
  • High ink laydown (up to 78 g/m2 at 25 m/min line speed*) delivers laminate designs with intense effects.

​Industrial reliability
The Xaar 2001+ family delivers maximum production uptime with minimum operator intervention for high production output and a fast return on investment.

  • Xaar TF Technology® ink recirculation ensures continuous ink flow at a high rate directly past the back of the nozzles during drop ejection; air bubbles and unwanted particles are carried away – maintenance is reduced to typically once per shift or less
  • The XaarGuardTM nozzle plate provides highly effective protection from mechanical impact so that production interruptions are minimised
  • With Xaar’s Tuned Actuator Manufacturing process actuator performance is optimised to ensure that print quality is consistent across all the printheads in a bar, and at different greyscale leve
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  • New XaarSMARTTM technology reports ink temperature and printhead status in real time so that printer performance can be easily adjusted to deliver consistent print quality throughout the production run.

Please Contact Us to find out more.

Printheads for laminates