R316: Specialty Resin Ribbon

Industry News and Markets: Flexible Packaging and UV Labels

Introduction A good overview of matching a thermal transfer ribbon to a suitable label is quite easy to grasp. Wax and wax/resin ribbons are usually printed on paper or synthetic paper labels; resin ribbons are usually printed on polypropylene or polyester labels. Indeed, common sense and technical limitations will soon re-enforce these maxims if needed. Wax and wax/resin ribbons will easily print on polyesters or polypropylenes, but it will soon be apparent that the label, in such a case, is a much higher-performing material than the inks being printed on it. In other words, the application that demanded a polyester or polypropylene label in the first place is likely to be too demanding for a wax or wax/resin ribbon. Similarly, a durable resin ribbon printed on a paper or synthetic paper will, in a challenging environment, break down before the resin ink does. However, this comparison can only be stretched so far; in actual fact, it is often difficult, if not impossible, to print resin thermal transfer ribbons on papers or synthetic papers. Still, niches for printing on paper, synthetic paper, or other materials with a resin ribbon do exist, and for these applications, DNP's R316 - a resin ribbon especially formulated for printing on coated paper labels and tags - fits the bill.

R316: Use as an enhanced wax/resin
R316 is designed to print on the same type of labels as are usually printed with wax and wax/resin ribbons, such as coated papers and synthetic papers. This means that it is a prime candidate for wax/resin applications where extra abrasion resistance is required. R316 has seen use in high stress warehousing and inventory applications, essentially applications of short- to medium-term use where there is a higher risk of damage to the product and its label and a wax or wax/resin does not provide sufficient protection against data or information being corrupted.

Test samples of the following ribbons were printed on Fasson 1C with a Zebra 140 XiIII printer: DNP R316, Dynic S-3, ITW M95, Ricoh B110A, and Armor APR5. All of these ribbons are highly-rated wax/resin ribbons. The samples were then subjected to 100 cycles of an Atlas CM-5 crockmeter with a 900 gram arm. The results are shown below in Figure 1.

	DNP R316
	ITW M95
	Dynic S3
	Ricoh B110A
	Armor APR5>

Figure 1: Comparison of abrasion resistance of R316 and wax/resin ribbons on Fasson 1C

Comments: R316 is clearly superior to most of the other ribbons tested here, for which there is clearly some damage to the printed image. The one possible exception is ITW's M95; however, closer inspection around the human-readable text beneath the bar code shows some smearing.

Flood-Coated Labels and M265 | Flat Head Flexible Packaging Applications with M265

R316: High Temperature Applications
The ink melting point of R316 is moderate, but, like all resin ribbons, the state change at the melting point is not a clear-cut transition from a solid to a liquid. More accurately, R316's ink becomes a slightly tacky version of its solid state, and further increase above the melting point temperature does not change the characteristics of R316 very much. Indeed, while other DNP resin ribbons - and resin ribbons manufactured by DNP's competitors - fail at much lower temperatures, testing at DNP's laboratories in Japan rate R316 to be functional in applications where the temperature rises as high as 428°F or 220°C (click here to see the R316 Technical Data Sheet).

R316 has found a lot of use in applications where the applied label is subsequently passed through a shrink tunnel. A typical operating temperature to make shrink film activate is around 350°F, considerably below R316's high operating temperature.

In the real world, even DNP's figure of 428°F as an operating limit may be conservative. Polyonics is a manufacturer that makes a range of labels designed for attachment to recently finsihed metal. These labels are constructed on a metal substrate; a plastic substrate would melt. As can be seen at this link

, Polyonics recommends R316 for use on a substrate recommended for temperatures up to 1150°F. To request a sample of R316, e-mail DNP's Sales Support Department, or call at 1-800-814-4672 and select option #2.

DNP Technical Bulletin: April 2006

M265: Specialty Wax/Resin Ribbon for Flood Coatings, Varnish Coatings, and Flexible Packaging Applications

Industry News and Markets: Flexible Packaging and UV Labels

Introduction
DNP's M265 Specialty Wax/Resin was initially developed for printing on flexible packaging materials.However, the technology that was developed to print on flexible packaging materials, with its emphasis on adaptability to "hard to print" substrates, has been found to lend itself to printing on other more challenging surfaces, such as flood-coated and varnished labels.Although M265 is quite capable of printing on regular thermal transfer label stocks, this article will examine its performance on flood-coated labels, varnished (OPV) labels, and flexible packaging films.

Varnish Coated Labels and M265 | Flat Head Flexible Packaging Applications with M265 Flood-Coated Labels and M265
There are very few thermal transfer-specific labels that are not white.(Probably the majority of non-white thermal transfer labels are "silver" or "chrome" polyesters designed for resin TTR printing, which are outside the scope of this article.)If an end user requires a non-white label, the usual solution is to apply an ink of the desired color to the label while it is being converted, a process known as flood coating.While this is a good value-adding service to offer and is in demand - for example, for supermarket shelf price tag labels - it has the disadvantage of making the finished label much less receptive to thermal transfer printing. One of the most commonly held myths about adding coatings to thermal transfer labels is that if a flood coat ink is added to a thermal transfer label, the end result is a thermal transfer label of a different color that retains the same printability as the uncoated label.This is not so.In technical terms, what the addition of a flood coat to a label does is to decrease the surface energy of the label. A good way of thinking about this is that water dropped onto the surface of a flood-coated label is more likely to "bead" than it was on the surface of the uncoated label. Just as the water is now less able to "flow" on the surface of the flood-coated label than it was on the uncoated label, so ink is much less able to "flow" away from the ink ribbon and onto the label.

As a result, thermal transfer printing carried out on flood-coated surfaces is often incomplete and irregular. When transfer does take place, what is printed often lacks scratch resistance. Figure 1 shows the advantage that M265 has on flood-coated labels against regular wax ribbons.


Figure 1: Comparison of M265 and other wax ribbon on flood coated label

The wax ribbon has actually printed quite well, but closer inspection reveals its shortcomings when compared to M265.Ink transfer of the text has been incomplete; notice the bottom of the upper-case 'W' in 'Wax' at the top of the label.A similar effect is seen with the graphics; the top of the rectangle for the label printed with the wax ribbon is indistinct.More importantly, if the the two bar codes are compared, the far right-hand narrow element of the bar code printed with the wax ribbon has failed to print; the bar code would not be scannable.Both bar codes were also scratched lightly with a fingernail, not a great force in thermal transfer terms. The wax ribbon showed signs of wear much more quickly than it would have were the print surface a white, "off-the-shelf" paper thermal transfer label, whereas M265 showed no sign of damage to the bar code at all.

Flood-Coated Labels and M265 | Flat Head Flexible Packaging Applications with M265

Varnish Coated Labels and M265
Many of the same problems encountered with printing thermal transfer ribbons on flood-coated labels are also found in printing on varnishes (also known as OPV's, or over-print varnishes). This occurs despite the fact that today there are label varnishes specifically formulated and promoted for use with thermal transfer.

Varnishes are used to give an extra level of protection to the label, but can also be used to improve the label's appearance.They are often applied to prime labels that are then applied to food, beverages and other retail products.They provide a label with added protection against moisture exposure, chemicals, scratches and abrasion.There are two main types of varnishes used for coating labels: water-based and UV-cured.Wax thermal transfer ribbons are generally unable to attach themselves securely to varnishes of either technology.UV varnishes are more easily imprintable with resin ribbons, while water-based varnishes tend to be receptive to both wax/resins and resins.

Nonetheless, there remains the problem that the dried varnish (especially the cured UV varnish) is fundamentally a low energy surface.Matters are further complicated by the fact that even a high-performing varnish can lose its efficacy for thermal transfer printing if it is coated incorrectly.However, Figure 2 shows how favorably M265 performs against another wax/resin ribbon.


Figure 2: Comparison of M265 and other wax/resin ribbon on OPV (varnish) label

By comparison with the M265 image, the other wax/resin produces an image that is much less sharp.The edges of the block and the line are much less distinct, and there is incomplete transfer of ink for the title words "Wax/Resin".The smaller text is not legible, and the bar code has not completely transfered, leaving it unscannable.

Flood-Coated Labels and M265 | Varnish Coated Labels and M265

Flat Head Flexible Packaging Applications with M265

As noted in the DNP Technical Bulletin for October 2005, there has been extensive growth in the past few years - with greater growth projected in the years ahead - in the use of thermal transfer printing in the marking of flexible packaging.However, most of this growth has taken place in the market for near edge thermal transfer printers, with brands like Markem, Jaguar and Videojet leading the way.In spite of this, there remains a market for flat head thermal transfer printing.

It is not surprising that near edge has led the recent growth in flexible packaging thermal transfer printing, as the technology has inherent properties that make it a "good fit" for flexible packaging applications.Near edge ribbons will print faster, making them more easily integratable into high speed in-line packaging applications.They will also print on practically anything; the usual rules that apply to flat head printing on synthetics, where a label must be treated or coated in some way to print well, do not apply.The floating head of many near edge printers also makes the handling of thicker substrates much easier than with flat head printers, where the print head is always fixed.However, with all these advantages comes one major disadvantage: it is extremely difficult to achieve the same kind of image durability from near edge ribbons that is possible with flat head ribbons.


Figure 3: Example of M265 as a solution for printing on flexible packaging

By comparison, flat head ribbons will often not be able to run at the line speeds required for in-line printing.More damagingly, flexible packaging films, for reasons both practical and aesthetic, are usually smooth and shiny, a very difficult surface for flat head thermal transfer ribbons to print on.Finally, whereas the top coat of a thermal transfer label is specifically designed to ensure the clear rendering of an image and give it durability, such considerations are of little importance in the design of flexible packaging films.Printing most flat head ribbons on flexible packaging films will usually give - where any ink transfers at all - irregular or indistinct printing, with incomplete ink transfer and voids in the print pattern.

DNP's M265 overcomes many of the limitations that regular flat head ribbons have on flexible packaging surfaces.It is built on the same platform as DNP's R316 Specialty Resin, and retains that ribbon's high-speed printing capabilities as well as nearly matching it for durability.

As a result, critical information can be printed on packaging material with a high degree of confidence that it will retain legibility.Despite the R316 platform, M265 can be printed at very moderate heat settings, typical of DNP's other wax/resins (e.g. M260).

To request a sample of M265, e-mail DNP's Sales Support Department, or call at 1-800-814-4672 and select option #2.

DNP Technical Bulletin: March 2006

R300 General Purpose Resin: Technical Bulletin II

Last month, the DNP Technical Bulletin examined the sensitivity, abrasion resistance, and market position of its R300 General Purpose Ribbon. This month, R300's solvent resistance and high speed printing performance will be examined. Also presented below is a discussion of UL and CSA certification for thermal transfer ribbons, as well as a list of some of R300's UL- and CSA-recognized ribbon, label and printer combinations.

For more details concerning performance and product applications for R300 and the entire DNP product line, call the DNP Product Developement Department at 1-800 814-4672, and select option 3. To view or download the R300 Technical Data Sheet, click here.

Applications and Product Information: Labels, Printers, and Products

Solvent Resistance: R300 and its Competitors

Thermal transfer printing is often the chosen print method if solvent-resistant variable information printing is required, and resin thermal transfer ribbons offer the best resistance to a wide variety of solvents. Testing was carried out to measure resistance against the folowing solvents:

• Isopropyl Alcohol (IPA)
• Gasoline
• Kerosene
• Brake Fluid

The ribbons tested, as well as the printer settings used, are shown below:

Ribbons:	Armor AXR-7	Ricoh B110C	Dynic HL21	DNP R300
	ITW R90	IIMAK SP-330	Sony TR-4075	Sony TRX-75
Label:	FLEXcon 21940
Printer:	Zebra 140XiIII
Print speed:	4"/s

The test pattern shown in Figure 1 was used for this test. The print energy chosen for each ribbon was the optimum energy for producing a scannable picket bar code on Flexcon 21940. After printing, the bar code is scanned once to verify a pre-test ANSI grade "A" scan. It is then attached to a Atlas CM5 Crockmeter fitted with a 900 gram arm. An amount of the solvent being tested is applied to the cotton gauze pad that covers the acrylic finger at the end of the arm. The crockmeter is then run for 10 cycles, with the path of the finger passing diagonally over the bar code. After this, the bar code is scanned again. The test stops if the scan produces a failing grade, in which case the number of cycles run prior to failure becomes the ribbon's score for the solvent being tested. If the barcode passes, additional instances of 10 cycles are run, with a scan of the bar code after each, until a failing grade is obtained.



Fig 1: DNP Solvent Test Pattern

The graph below was created from the combined results of tests for each ribbon for each solvent. A higher score shows greater overall resistance to the solvents tested.

Fig 2: Overall Solvent Resistance Performance: Zebra 140XiIII with General Resin Ribbons

Comments: Although not the best-performing ribbon against each solvent, the combined results show that R300 had the best overall performance.


High Speed Printing: R300 and its Competitors

Thermal transfer printing has always had the advantage of being able to print at high speeds. This characteristic has made the integration of thermal transfer printers into in-line manufacturing processes very popular. However, many resin ribbons have often not been able to match the print speeds of wax or wax/resin ribbons. Testing was conducted to compare the performance of the ribbons listed below on a Flexcon 21940 label at the print speeds shown:

Ribbons:	Armor AXR-7	Ricoh B110C	Dynic HL21	DNP R300
	ITW R90	IIMAK SP-330	Sony TR-4075	Sony TRX-75
Label:	FLEXcon 21940
Printer:	Zebra 140XiIII
Print Speed:	4"/s, 6"/s, 8"/s, 10"/s, 12"/s
Print Energy:	+15 to +27 (increments of two)

The print pattern used was the standard DNP test pattern, as shown in Figure 3.



Figure 3: DNP Standard Test Pattern

After printing, the picket and ladder bar codes for each label were scanned. In the graph below, higher scores are assigned to ribbons with more ANSI passing grade picket and ladder bar codes at higher speeds.



Fig 4: High Speed Printing Performance: Zebra 140XiIII with General Resin Ribbons

Comments: At a speed of 12 inches per second, R300 is regularly able to print ANSI grade "A" ladder bars on some labels. Some of the other ribbons tested here, by contrast, print very poorly or not at all at speeds as low as 8 inches per second.

R300: UL and CSA Certification

UL and CSA certification is often a requirement for qualifying a ribbon for a particular application. However, there are a lot of misconceptions about the process and the scope of UL and CSA certification for thermal transfer ribbons. Below is a primer on the subject.

1. UL Certification is given only to a system of one distinct ribbon and one distinct label.
• To say that "R300 is UL-certified" could be true but is also extremely misleading, as it does not give all the information necessary to qualify the statement.
• IT SHOULD NEVER BE INFERRED THAT JUST BECAUSE R300 IS UL-CERTIFIED ON A PARTICULAR LABEL, IT IS UL-CERTIFIED ON ANY OTHER LABEL.
  • This is because if UL Certification is given to an ink (for example, a thermal transfer ribbon) for printing on a label, it cannot be given to the ribbon alone.
  • An example of a more precise statement is "R300 is UL-certified on Fasson 72826" (both ribbon and label are mentioned).
2. CSA Certification is given only to a system of one distinct ribbon, one distinct label, and one distinct printer brand.


• Each of the following statements could be true but is also extremely misleading:
• "R300 is CSA-certified" - (label or printer not mentioned);
• "R300 is CSA-certified on Fasson 72826" - (printer not mentioned);
• "R300 is CSA-certified for use on a Zebra printer" - (label not mentioned).
• IT SHOULD NEVER BE INFERRED, FROM ANY OF THE ABOVE STATEMENTS, THAT R300 IS CSA-CERTIFIED ON ANY LABEL.
• This is because if CSA Certification is given to an ink (for example, a thermal transfer ribbon) for printing on a label, it cannot be given to the ribbon alone.
• A more precise statement is "R300 is UL- certified on Fasson 72826 on a Zebra printer" (ribbon, label and printer are all mentioned).
3. Ownership of UL and CSA Certifications for ink systems on labels always falls to the label companies. DNP holds no documentation from either UL or CSA on the status of their ribbons in these agencies' programs. If a customer needs documentary evidence of a ribbon's certification, it is recommended that the customer contacts the label company or checks current listings at UL's website (www.ul.com), or CSA's website (www.csa.ca).

Below are two lists showing some of R300's UL-certified pairings of ribbon and label, as well as some of the groupings of R300, label, and printer certified by CSA. These lists are by no means exhaustive; further information can be found by referenceing the links to the UL and CSA web sites given above.

UL Certifications: Labels with R300

3M 7815	3M 7816	3M 7819
Fasson 72825	Fasson 72826	Fasson 72828
Flexcon 21830	Flexcon 21940	Flexcon 21970

CSA Certifications: Labels and Printers with R300

Fasson 72825 on on all Zebra, Datamax, Sato, and TEC Printers.

Fasson 72828 on on all Zebra, Datamax, Sato, and TEC Printers.

DNP Technical Bulletin: February 2006

R300 General Purpose Resin: Technical Bulletin I

In the next two months, the DNP Technical Bulletin will explore all application, performance and conformance issues connected to its R300 General Purpose Ribbon. R300 is here being classified as a general purpose ribbon. This description has been made all the more appropriate given the development in the market of thermal transfer resin ribbons during the past few years. A few years ago, there were fewer resin ribbons on the market, and the performance of these ribbons tended to be quite similar. However, in the past few years, many manufacturers have launched ultra-durable resins; DNP's R510 is one such ribbon. Applications for these ultra-durable resins are often highly specialized niches, calling for resistance to abrasion, solvents and heat to an even greater level than the general purpose resins. Although the market for such applications is growing, the availability of suitable labels to print the ultra-durable resins can add to the difficulty of implementing these ribbons in an application. Therefore, it is strongly advised that when a new application calling for a resin ribbon presents itself, R300 should be tested first. For more details concerning performance and product applications call the DNP Product Developement Department at 1-800 814-4672, press option 3.

Applications and Product Information: Labels, Printers, and Products

Labels chosen for particular applications suitable for general thermal transfer ribbons will have one or more of the following performance requirements:

• Resistance to harsh environments
  • Heat
  • UV light exposure / long-term outdoor exposure
  • Moisture
• High scratch and smear resistance
  
  
• Chemical resistance
  
  
• Label marking where projected lifetime of label is more than two years

However, all these desirable performance characteristics often come with the cost of higher print energy requirements, often so high that print head life is severely reduced. Another common problem with resin ribbons is that they will often need to be printed more slowly than their wax or wax/resin equivalents. This can be especially problematic when printing is integrated in an in-line manufacturing process; label print speed should never becomes the limiting factor in the speed of the whole line. DNP's R300 overcomes many of these drawbacks. As well as providing excellent abrasion and solvent resistance, it requires less than average printer energy settings to image, and, on many substrates, it will print with the highest quality even at print speeds of 12 inches per second. Applications
Typical applications where R300 can be deployed include asset tracking labels, automotive labeling, and applications in the pharmaceutical and healthcare fields. Chemical drum labeling applications are also recommended; in applications like these, R300's resistance to solvents, abrasion, and outdoor exposure all serve to make it a good choice. Further applications and technical data can be found in the R300 Technical Data Sheet. Sensitivity: R300 and its Competitors
A ribbon's sensitivity can be thought of as the inverse of the amount of print energy that is required to print it: that is, if a ribbon requires high heat to be printed, its sensitivity is low, and if it requires low heat, its sensitivity is high.

This distinction is important whether the type of thermal transfer ribbon being used is wax, wax/resin, or resin, as a higher required operating temperature means more work for the print head to do, which can lead to shorter print head life and higher operating costs as the print heads are replaced. With resin ribbons, however, sensitivity becomes even more of an issue. Operating a wax ribbon one or two heat settings above the setting required for another ribbon will make little difference to print head life in the long run, as required settings for wax ribbons are always moderate. Resins, by contrast, need much higher heat to print successfully, and it is not hard to start to push the print head's operating temperature into regions where the print head will start to overheat, and operating stresses on the print head will start to multiply. In short, a more sensitive resin ribbon will reduce operating costs, cutting the frequency of print head replacement along with the lost production time needed for the repair.
Fig 1: DNP Test Pattern

The DNP print pattern used for these tests is shown above. The recorded print energy for each ribbon in the graphs below is the lowest energy at which both picket and ladder bar code of the DNP test pattern scan an ANSI grade A, or, if no ladder bar with an ANSI A could be printed, the print energy where the highest ANSI grade-scanning ladder bar was printed.

The graphs were created from tests conducted with the following ribbons, labels, and printer. Results show the required print energy for each ribbon/label combination: therefore, a shorter bar indicates lower print energy and therefore, higher sensitivity and less stress on the print head.

Ribbons:	Armor AXR-7	Ricoh B110C	Dynic HL20	Dynic HL21
	NCR K-3	DNP R300	ITW R90	Sony Signature Resin
	IIMAK SP-330	Sony TR-4070	Sony TR-4075	Sony TRX-75
Label:	FLEXcon 21940
Printer:	Zebra 140XiIII
Print speeds:	4"/s to 12"/s
Heat settings:	+11 to +27

Fig 2: Print Energy Requirements: Zebra 140XiIII at 4"/s with General Resin Ribbons


Fig 3: Print Energy Requirements: Zebra 140XiIII at 12"/s with General Resin Ribbons It can be seen that at 4"/s, DNP's R300 is equal in performance to other ribbons that require the least energy to print. By the time the print speed has been increased to 12"/s, R300 has the advantage over all other ribbons tested, requiring the least print energy; indeed, this advantage is seen at print speeds as low as 8"/s.

Abrasion Resistance: R300 and its Competitors
The primary reason for choosing a resin ribbon ahead of a wax or wax/resin combination is an application requirement for higher resistance to scratch and smear. The graph below is shows the results of a test conducted with a Taber 5130 Abraser . Test strips (See Figure 4) were printed on FLEXcon 21940.

Fig 4: Abrasion Test Bar Code The abraser is fitted with CS-10 wheels, and each arm is weighted to 500 grams. Test strips are scanned with a Quick Check 650 Verifier to check for a starting "A" grade. The abraser is then run for 10 revolutions and the sample is scanned again. The value represented in the graph below (Figure 5) is the number of completed turntable revolutions at which the bar code gives its last good scan. For example, if a ribbon in the graph below receives a score of 40, this means that the label with which it was printed scanned successfully (ANSI Grade A, B or C) after forty revolutions, and either gave a failing scan (ANSI D or F) or did not scan after fifty revolutions.


Fig 5: Abrasion Resistance on FLEXcon 21940 using Taber 5130 Abraser

As can be seen, R300 is again equal in performance to the most abrasion-resistant ribbons tested here.

R300: Suitable Labels

Suitable labels for R300 are most commonly polyester or polypropylene labels designed for resin thermal transfer printing. These labels can either be print-treated or topcoated to provide a suitable printing surface; labels from manufacturers such as Fasson, FLEXcon, 3M, Mactac and many others have been found to be suitable for R300. In addition, there are labels that are most often thought of as compatible with wax/resin thermal transfer ribbons - for example, Kimdura and Valéron VMAX - that can be printed with R300, although print speeds will have to be reduced and print energies increased for best results.

R300: Suitable Printers

R300 can be printed with any regular flat head thermal transfer printer, such as those made by Zebra, Datamax, Intermec and Sato.

DNP Technical Bulletin: January 2006

DNP Secure Printing Technologies: Applications with Fasson® Security Labelstocks

Labels, Printers and Product | FAQ's

Industry News and Markets: Security-Holograms and UV

Holograms and UV Defined
Holograms and UV are optical devices used throughout the security and brand protection market segments. They cannot be replicated with current printing techniques, color copiers, or specialized computer equipment (easily purchased by the public sector).
They are also a widely accepted device for providing various levels of security to a product or document.

Hologram - the hologram belongs to a class of images known as Diffractive Optical Variable Image Device (DOVID). It is a unique photographic printing that provides a two- or three-dimensional effect on a flat surface. They cannot be easily copied and are used for security and aesthetic applications.

Ultraviolet Ink - ultraviolet inks are materials that will fluoresce under ultraviolet light producing colors or light that our eyes can see. The ink remains invisible to the eye when not exposed to an ultraviolet light source.

End Users
DNP's hologram and UV security products have been developed to support the business owner that requires an affordable, less sophisticated security solution. They are typically business owners whose products range from special event tickets and government documents to collectibles. They typically battle the "casual counterfeiter" - someone using fairly unsophisticated technology (a computer or scanner) that can be purchased in a retail outlet. A more in-depth discussion of DNP's UV and Hologram Security Products can be found in the September 2005 DNP Technical Bulletin. For more details concerning performance and product applications call the Product and Services Department at 1-800 814-4672, press option 3.

Security Markets, Holograms and UV | FAQ's

Applications and Product Information: Labels, Printers, and Products

DNP Hologram and Ultraviolet (UV) Thermal Transfer Ribbons are resin-based, high durability security products that can be printed with any regular flat head thermal transfer printer. All of the examples shown below were printed using regular flat head thermal transfer printers, such as Zebra, Datamax, Sato, and Intermec.Further details about the design and manufacture of the hologram and UV ribbons can be found at
September 2005 DNP Technical Bulletin. Fasson's Security Labelstocks employ a wide range of product features to enhance the security of the finished label. Many of these labelstocks are thermal transfer-imprintable, and so can be combined with DNP's UV and Hologram ribbons - as well as ribbons from DNP's core product line - to produce custom security solutions. Examples of many of these labels are shown below, with links and a summary of the security features of the label and the DNP ribbon used to print on it.

DNP Custom Holographic Ribbon
	Label: Fasson Holographic 77644
	Label Description: 1 Mil Holographic SFYP (Sealed For Your Protection) Polyester TE (Tamper-Evident)
	Label Security Feature: Holographic, with tamper- evident security feature featuring a checkerboard tear pattern. The words "Sealed For Your Protection" appear in both English and Spanish.

DNP M260 Premium Wax/Resin
Label: Fasson Foamseal TE 77647
Label Description: Tamper-evident polystyrene facestock.
Label Security Feature: Facestock delaminates upon removal from the substrate.

---

DNP R300 and Rose Hologram Ribbons
Label: Fasson Holographic 77644
Label Description: 1 Mil Holographic SFYP (Sealed For Your Protection) Polyester TE (Tamper-Evident) with two-pass TTR printing
Label Security Feature: Holographic, with tamper- evident security feature featuring a checkerboard tear pattern. The words "Sealed For Your Protection" appear in both English and Spanish.

DNP R316 Specialty Resin
Label: Fasson 77614
Label Description: Clay-coated, biaxially-oriented HDPE
Label Security Feature: Low internal bond/cohesive strength, which allows the facestock to delaminate and shred upon attempted removal.

---

DNP W160 Durable Wax and UV Ribbons
Label: Fasson 18872
Label Description: 60# UV SCR (Solvent and Chemical Reactive) Security Paper with two-pass TTR printing.
Label Security Feature: Label contains invisible ultraviolet fluorescent fibers that confirm both immediate authenticity, using a black light, and long term authenticity, as fibers are not present in a photocopied document.

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DNP Fish Scale Hologram Ribbon
Label: Fasson Holographic 77644
Label Description: 1 Mil Holographic SFYP (Sealed For Your Protection) Polyester TE (Tamper-Evident)
Label Security Feature: Holographic, with tamper-evident security feature featuring a checkerboard tear pattern. The words "Sealed For Your Protection" appear in both English and Spanish.

---

DNP R300 General Purpose Resin and Rose Hologram Ribbons
Label: Fasson 41100 (Tamperfas)
Label Description: Matte white vinyl label with two-pass TTR printing
Label Security Feature: Label delaminates on attempted removal from surface.

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DNP R300 General Purpose Resin and Windmill Hologram Ribbons
Label: Fasson 77649
Label Description: 2 Mil White Diacetate TE (Tamper Evident)with 2-pass TTR printing
Label Security Feature: Low tear strength, incorporating a higher level of destructibility over traditional acetates

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DNP R316 Specialty Resin and UV Ribbons
Label: Fasson 13103
Label Description: 50# C1S litho with 2-pass TTR printing.
Label Security Feature: Highly destructible stock.

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Security Markets, Holograms and UV | Labels, Printers and Product

Technical White Papers and FAQ's: Holograms and UV

What is DNP Secure Printing Technology?
DNP has developed a line of hologram and UV, resin based, thermal transfer ribbons focused on applications requiring brand protection, authentication, and identification. This technology allows the end user to print on-demand, variable information in real time. DNP offers four stock patterns and will also develop a custom hologram based on end user requirements.

What are applications for Security Holograms and UV?
Below are a few applications utilizing hologram and UV security devices:

Security and Authentication
Security: Currency Credit Card Stock Certificate Legal Document Government Document ID Badge Passport Prescription Pad Drivers License Automobile Registration Event Tickets Lottery Tickets Stamps	Authentication (Brand Protection): Tobacco Apparel Liquor Computer hardware Auto and Aircraft parts Sporting equipment Software Electronic devices CD's DVD's Machinery Medical devices Pharmaceuticals

What are the benefits of thermal transfer security holograms and UV?

Hologram and UV thermal transfer ribbon benefits:
Ø Authenticates a product allowing the end user to be assured it is not a counterfeit.
Ø Reduces the likelihood a product can be counterfeited.
Ø Preserves the manufacturer's revenue by hindering the counterfeiter's ability to copy the product. Provides on demand, variable information that can be printed in real time. Holograms are barcode scannable, allowing an additional layer of security.

What is an overt and covert security device?

Overt - a hologram is an overt security device. This means that it is visible to the naked eye and does not require special methods or equipment to view the hologram. Covert - UV is a covert device. This means that it is not visible to the naked eye and requires a device to see the image.

Can these holograms be customized?

Yes, DNP can customize a hologram to the customer's specifications. Once the customer approves the hologram, the image will be registered in the Hologram Image Register (HIM), which is supported by the International Hologram Manufacturers Association (IHMA). DNP is a member of this organization and provides access to the HIM for customers requiring custom holograms. This registration will add an additional layer of security for the hologram design. Click here for additional information.

What types of printers can these products be used with?

DNP's holograms are used in flathead printers only: Zebra, Sato, Intermec, Datamax, and many others.

What substrates are compatible with holograms?

Polyesters, polypropylenes, PVC and synthetic papers. For a table showing recommended substrates,click here.

What substrates are compatible with UV?

Polyesters, polypropylenes, and PVC. For a table showing recommended substrates, click here.

How long can UV be exposed to sunlight before degrading in performance?

DNP's UV Specialty Resin TTR has been developed to withstand extended periods of outdoor sunlight exposure without excessively degrading its fluorescent qualities. For a graph showing preservation of fluorescent intensity over time, click here.

Can UV and other resin-based thermal transfer ribbons be printed over holograms? Yes, UV and other DNP resin-based thermal transfer ribbons have been designed to print over the hologram.

By layering devices such as these, the end product becomes much more difficult for counterfeiters to copy.

Industry News and Markets: TTR Back Coat Performance Comparison

Introduction
Nobody would dispute the need for regular maintenance of a thermal transfer printer. There is no argument that keeping the print path clean can save time and money in the long run. Nor is there any disagreement that regular cleaning of the thermal print head is necessary to ensure print quality and prolong print head life - such schedules are vigorously promoted by the printer manufacturers. However, one of the primary functions of the back coat of a thermal transfer ribbon is to minimize the amount of build-up that occurs on the thermal print head. Testing recently conducted at DNP suggests that the in-line lightly abrasive cleaning card now included with another leading TTR manufacturer's ribbons is needed to combat the relative performance of the manufacturer's back coats.

Background
Debris can easily accumulate on the rollers, guides, and plates over which the ribbon and labels of a thermal transfer printer pass. There are many sources of contamination in a typical work environment, including adhesive and paper dust from the labels, airborne particles, and environmental contaminants. Accumulation of any contaminates on any of the parts of a thermal transfer printer can be troublesome and can certainly affect print quality, but it is build-up on the thermal print head that is most damaging and costly. Build-up on a print head can, in short time, seriously affect print quality, cause production downtime, and lead to the replacement of the print head - all factors that impact operations and increase the cost of ownership.

Figure 1: Clean print head

Figure 1 shows a clean print head. The squares running across the middle of the picture are the individual print head elements, also known as dots. These elements produce the heat necessary for the ink to transfer to the label from the ribbon, and it is on these elements that build-up will usually be found.

Function of the back coat
A thermal transfer ribbon back coat has many functions. It provides:

• Lubrication: Smooth travel over the print head will lead to consistent, high-quality printing.
• Heat conduction: Efficient delivery of heat from the print head to the ink side of the ribbon must be maximized.
• Cleaning: If any debris does reach the print head, the back coat can remove it before it starts causing print problems.

High back coat performance is all the more important if the print pattern is dense, if print runs are long, or if the print speed is high. Improper cleaning of the print head can lead to print head build up - causing poor print quality - which will compromise the print head's ability to transfer heat. This will eventually lead to failure of one or more print head elements and the need to replace the print head. DNP has always focused its design efforts on developing back coats that minimize build-up. With this focus in mind, development always begins and ends with the functionality of the back coat. All other things being equal, a bad back coat can lead to print head build-up regardless of outside contaminants.

Printer Manufacturer's Recommendations and Other Ribbon Manufacturer's Responses
To prolong print head life, OEM printer manufacturers recommend that the print head be cleaned after every ribbon. In the real world, this is rarely done. Most end users will only clean their print heads if there are signs of print deterioration. A further impediment is the perception that stopping a production process and cleaning with IPA or a cleaning card interrupts production flow. One of DNP's leading competitors is marketing a lightly abrasive plastic cleaning card, provided in-line on the ribbon, spliced between the lead film and the ink ribbon. The manufacturer believes it has provided a quick and convenient solution for regular print head cleaning. However, DNP has proven, through years of development experience and infield testing, that a high-quality back coat is the primary factor in reducing print head build up and prolonging the life of the print head.

Test Procedure

Test Equipment and Settings: Printer: Zebra 140XiII
Speed: 8 inches / second
Heat: +17
Ribbons used:

• DNP W137
• Competitor A: Wax Ribbon With In-Line Cleaning Card
• Competitor B: Other Leading Wax Ribbon

Test Pattern:

Figure 2. Print test pattern

? - Ladder bar code; , - 100% Duty Area; f - Picket bar code

The print pattern is shown in Figure 2, with the corresponding test areas called out: the ladder bar area (designated ? ), the 100 % duty area (designated , ) and the picket bar area (designated f ). DNP printed 3000 meters of the pattern shown above on a standard thermal transfer paper label using a Zebra 140 XiII printer. A new print head was used for each ribbon; after 3000 meters, photographs were taken in three distinct areas of the print head.

Results and Conclusion

Test Area ? - Ladder Bar Code: Results and Comments

	Figure 3: Competitor A (Wax Ribbon With In-Line Cleaning Card) - Ladder Bar Area
	Figure 4: Competitor B (Other Leading Wax Ribbon) - Ladder Bar Area
	Figure 5: DNP W137 - Ladder Bar Area

Figures 3, 4 and 5 show the print head area used to print the ladder bar code, Test Area ? . Printing ladder bar codes is one of the most stressful operations things a print head can perform, and puts equivalent stresses on the back coat. With build-up on the burn line of the print head, heat transfer becomes inefficient as residual heat is retained in the built-up material. The effect of this is to make both the leading and the trailing edge of the bar code elements less sharp and less likely to provide a good scan. Figure 3 shows considerable build-up coming from the Competitor A's ribbon (Figure 3), and slightly less from the other leading wax tested (Figure 4). However, by comparison, build-up is minimal to none on the print head tested with DNP's W137 (Figure 5).

Test Area , - 100% Duty Area: Results and Comments

	Figure 6: Competitor A (Wax Ribbon With In-Line Cleaning Card) - 100% Duty Area
	Figure 7: Competitor B (Other Leading Wax Ribbon) - 100% Duty Area
	Figure 8: DNP W137 - 100% Duty Area

Figures 6, 7 and 8 are images of Test Area , , the 100% Duty Area, designed to replicate typical build-up if an end user is printing large-scale graphics or fonts. After 3000 meters, build-up is again much more obvious on the print head used to print Competitor A's ribbon, as seen in Figure 6, and the print head used for Competitor B's ribbon (Figure 7). By contrast, DNP's W137 (Figure 8) leaves minimal build-up, very light compared to the other two ribbons.

Test Area f - 100% Duty Area: Results and Comments

	Figure 9: Competitor A (Wax Ribbon With In-Line Cleaning Card) - Picket Bar Area
	Figure 10: Competitor B (Other Leading Wax Ribbon) - Picket Bar Area
	Figure 11: DNP W137 - Picket Bar Area

Figures 9, 10 and 11 show an area of the print head used to print a picket bar code, Test Area . The two darker elements on the right of each picture represent the area from which the narrow bar of the bar code has been printed, and the group of five elements (most clearly seen in the 'Leading Wax' picture, Figure 10) represents a wide bar. Build-up is again greatest for Competitor A (Figure 9), least for DNP's W137 (Figure 11), with Competitor B (Figure 10) ranking between these two. Many of the same problems that arise from build-up for the previous two areas apply to the area of the print head used to print the picket bar. However, build up should, in theory, be more localized; there are, after all, spaces between the bars of a picket bar code - the print head dots in the spaces were not used in the tests conducted here. However, for Competitor A's ribbon, as seen in Figure 9, there is sign of build-up even on the unused dots.


Conclusion

Based on DNP's extensive testing, the ribbon with the in-line cleaning card produces the greatest amount of residue in all areas of the print head. DNP's back coat, by contrast, ranked #1 in all three areas of the print head.

DNP would never dispute that print head cleaning is a vital part of regular printer maintenance, or challenge OEM recommendations to clean the print head after each roll of ribbon. However, the inclusion of the in-line cleaning card with the ribbon that leaves the most build-up negates any advantage that the cleaning card might provide.

DNP Wax Resin Ribbon: M260

Industry News and Markets: M260 Wax/Resin Thermal Transfer Ribbon

Why Use A Wax/Resin Thermal Transfer Ribbon?
Wax/resin thermal transfer ribbons are used in applications requiring additional abrasion and chemical resistance not offered by a wax thermal transfer ribbon.

Wax/resins contain a small percentage of resin material allowing for improvements in abrasion resistance and chemical resistance over the properties of a standard wax thermal transfer ribbon. In addition to the wax/resin's physical performance characteristics, its ability to print on a wide assortment of labels is also a factor for choosing a wax/resin.

M260 is DNP's wax/resin product that offers excellent durability and chemical resistance. It has been specially formulated to print on a wide variety of paper and film-based substrates.

M260 was originally designed to combat the market leader, Ricoh B110A, with a design focus on offering unique features not currently satisfied by other wax/resins in the market place. During the product concept phase, DNP's product development team learned there were needs in the wax/resin market in three areas:

1. Print energy reduction: Cost of ownership is a primary criterion for many customers when choosing a print system and supplies. By lowering print head energy, the life of the print head is extended, ultimately lowering maintenance costs.
2. Substrate printability: More and more resin applications are being pushed down to wax/resins (due primarily to costs). In order to meet these requirements, wax/resin designers are being pushed to develop new carrier film and coating technologies to meet this demand.
3. Media consolidation: Customers are always looking for ways to reduce costs within their supply chains and inventory. By developing a wax/resin product that can print on a wide variety of substrates, the need for different types of thermal transfer ribbons is greatly reduced, thus reducing inventory costs.

In order to meet the various requirements demanded of a wax/resin, the product design team focused their efforts on coating and adhesive layer technologies.

By first attacking the print energy issue, the product development team combined their ability to coat thin films with existing release layer and ink layer technologies. Typically, a thermal transfer ribbon is manufactured with a 4.5 micron PET carrier film. In the case of M260, DNP combined its ability to coat 4-micron PET carriers with its existing hot melt coating technologies. By coating a 4-micron film, as opposed to 4.5-micron PET, less print energy is required to transfer the ink layer from the carrier film to the substrate. This advantage allows the customer to reduce their printer energy, thus reducing stress on the print head and extending its life. No other wax/resin in the market has printer energy requirements as low as M260.

The next design hurdle was to develop an adhesive layer compatible to topcoats used in wax and resin applications. This was successfully achieved by utilizing similar DNP technologies found in card and photo ID products.

Applications
Below is a list of applications utilizing M260:

• Extreme Environment: Heat tunnel shrink-wrapping requiring durability against material handling and to short-term exposure to high temperatures (500°F).
  
• Electronics: Surface mount technology processes requiring chemical resistance and short-term heat soaks (500°F).
  
• Inventory: Shelf tagging and labeling to aid supply chain management issues and Enterprise Resource Planning (ERP) systems.
  
• Logistics: Materials tracking and traceability of products moving through the supply chain or Work In Process (WIP).
  
• Healthcare: Labeling medical pouches, prescription bottles, medical device packaging, blood bags, and other medical/pharmaceutical packaging subjected to aggressive manufacturing processes, such as steam autoclave sterilization.
  
• Asset Tracking: Labeling for tracking expensive assets and capital equipment. Often used to control capital inventory as well as guard against theft.
  
• Retail: Shelf edge labels used to identify brand, unit of measure, price, expiration date, promotions, and product.
  
• Textile: Labels used to provide size, price, and description of garment. Typically alphanumeric characters.
  
• Automotive: Labels used for both supply chain management and product ID. Excellent durability is required.
  
• Horticulture: Tyvek, polypropylene, and polyethylene labels used with nurseries and retail garden centers. Primarily used for product description, pricing, and weight.

Recommended Substrates

Coated/Uncoated Paper Flood coats Synthetic paper Polyethylene Polypropylene

Polyolefin Kimdura Valéron Polyart Polyester

For technical support or help with matching a substrate to M260, click here to e-mail DNP's Product and Services Department.

Applications and Product Information: Labels, Printers, and Products

Ribbon Construction
A diagram of the basic construction of M260 is shown below (Figure 1). The HR layer (heat resistant layer) is the layer of the ribbon that comes into contact with the thermal print head. It has two main functions: it must provide lubricity to ensure smooth and even travel across the print head, and it must also provide good heat conduction to ensure that heat from the thermal print head can cross the PET film and reach the layers on the ink side of the ribbon.

Figure 1: Basic Construction of M260

The next layer is the PET film - the carrier film on which all of the other layers of the ribbon are coated. Whereas an industry standard - and a standard for most of DNP's other thermal transfer ribbons - is a film thickness of 4.5 microns, DNP chose to use a 4.0 micron film for M260. This lowers the required heat settings for this ribbon, but the film is still thick enough that the finished ribbon's structural integrity is not compromised.

The first layer coated on the ink side of the ribbon is the release layer. This layer encourages adhesion of the ink layer during the coating process and release of the ink during printing. Some thermal transfer ribbons will get their anti-static properties from this layer; for M260, this function is carried out by the adhesive layer (see below), which has enabled DNP's chemists to add more abrasion-resistant components to the release layer and improve the overall performance of the ribbon.

The next layer coated is the ink layer, which contains waxes, resins and colorant. The waxes used in M260 are predominantly hard waxes, which, along with the resins in the ink mixture, provide much of the high durability against abrasion and solvents.

The final layer that is added to M260 is the adhesive layer. This is the layer that actually attaches to the print surface. It gives M260 great versatility in the number and types of substrates on which it can be printed. As mentioned above, it also gives M260 its anti-static characteristics.


Ribbon Performance: M260 vs. Competitors' Ribbons

DNP has done extensive testing to compare the performance of M260 against other competitors' ribbons. Ribbons were evaluated for sensitivity, abrasion resistance, solvent resistance, and high speed performance.

The DNP standard print pattern (See Figure 2) was printed on a Zebra 140XiIII at energy settings of +3 through +19 in increments of two (default darkness on front panel = 0). The following speeds were used: 2 ips, 8 ips, and 10 ips.

The following labels were used:

Fasson Transtherm 2 Smudeproof Kimdura Arjobex Polyart Fasson Semi-Gloss Elite Fasson 72826 Fasson Transgloss Avery 01271 Avery 01944

Valéron Valéron Uncoated VMAX Valéron VMAX Mactac TT9002 3M Vinyl (3690E) Raflatac Vellum Fasson 40443 Fasson Acetate (60097)

Mactac KTT-133 Mactac MT9006 Mactac TL2601 Mactac MT8911 Tyvek Brillion FLEXcon 22440 FLEXcon 21650 FLEXcon 21440

M260 was tested against the following competitors' wax/resin ribbons:

Sony 4065 Ricoh B110A ITW M95

Sony TRX55 IIMAK PM350A Armor APR5

The four individual tests used to evaluate the ribbons' performance are described below:

1. Ribbon Sensitivity
The sensitivity of a thermal transfer ribbon is inversely proportional to the amount of heat needed to make it print; that is to say, a more sensitive ribbon will require less print energy, giving the print head less work to do and thus prolonging its life. The picket and ladder bar codes of each label were scanned with a PSC Quick Check 650 Verifier to ascertain the best performance as a function of print speed and print energy. Optimal performance gives a high ANSI grade for the bar code scan, but with a low print energy setting. All combinations of ribbon and label were printed at 2 ips, 8 ips, and 10 ips.

Results - Sensitivity
M260 > APR5 > TR4065 = B110A = TRX55> PM350A > M95

Comments: Higher ribbon sensitivity means lower printer heat settings, and thus longer print head life.


2. High Speed Printing Performance
Using the same data set and methodology as for the Ribbon Sensitivity test, the 10 ips data was examined to compare the high speed performance of each ribbon. Ribbons were judged on the degree of diminution of performance as the print speed increased. A lower ranking thus does not necessarily mean that this ribbon's performance is bad at higher speeds, but rather that the decrease in its performance at higher speeds in comparison to its performance at 2 ips is more pronounced than higher-ranking ribbons.

Results - High Speed Printing
M260 > TR4065 > PM350A = TRX55 = B110A > M95 > APR5

Comments: Higher print speeds mean that label printing is less likely to slow down the throughput of any manufacturing process into which the print process is integrated. M260 has been tested at 12 ips and found to print "A" grade ANSI ladder bar codes.


3. Abrasion Resistance
A single picket bar code was printed at its optimum energy and scanned to ensure an 'A' grade ANSI read. This bar code was then rubbed for 50 cycles using an Atlas CM-5 crockmeter, and the bar code was then scanned again. Again, all combinations of ribbon and label were used.

Results - Abrasion Resistance
M95 > M260 = TR4065 = PM350A = B110A = TRX55 > APR5

Comments: Despite the way it is marketed, within the thermal transfer industry M95 is often considered a low-grade resin ribbon. The result here is the clearest demonstration of this, but it should be noted that this is the only performance parameter examined here in which M95 has an advantage.


4. Solvent Resistance
The crockmeter was used for the abrasion test, but prior to the test, quantities of a solvent were applied to the tip of the crockmeter's rubbing finger. Solvents used for this test were brake fluid and IPA. "Before" and "After" ANSI grades were recorded, and all grades and scores combined to produce the graph below.

Results - IPA Resistance
M260 = TRX55 = TR4065 = B110A > PM350A > APR5 > M95

Results - Brake Fluid Resistance
PM350A > M260 = TR4065 > B110A = TRX55 > M95 > APR5

Comments: For solvent resistance, APR5 and M95 performed markedly worse than the other ribbons tested.


5. Overall Results
The results from the four tests above were combined to produce the overall ranking below:

Overall Results
M260 > TR4065 > B110A = TRX55 > PM350A > M95 > APR5

Comments: M260 is the only ribbon that ranked 1st or 2nd in all test categories.

Thermal Transfer Flexible Packaging Solutions

Labels, Printers and Product | Presentation

Industry News and Markets: Flexible Packaging

What is Flexible Packaging?
Simply put, flexible packaging is any non-rigid packaging - such as bags, pouches, and films - that is used to store a product (i.e. food, pharmaceuticals, fasteners, beverages...).

Market Overview:
Globally, flexible packaging is a $38 billion industry and is expected to grow 4.6 percent in 2005 and in the years to come. In the US, flexible packaging is a $21.3 billion industry and is the second largest packaging type, accounting for 17 percent of the US $124 billion packaging market.

The demand for flexible packaging in the US will continue to grow due to innovations in breathable films (improved barrier properties) and resealable stand-up pouches. Growth will also be driven by new applications and a shift in usage from rigid containers.

To date, food packaging remains the primary market for flexible packaging applications with secondary markets in pharmaceutical, medical, and industrial segments.

Thermal Transfer Market:
Flexible packaging applications, using thermal transfer printing technology, have an estimated market size of $15 million to $20 million (at the retail level) with expected growth rates of 10 percent to 15 percent over the next two years. The primary market segments that utilize thermal transfer technology are in Consumer Goods, Medical/Pharmaceutical, and Industrial.

Industry Drivers:
Fostering the growth of thermal transfer technology, within the Consumer Goods, Medical/Pharmaceutical and Industrial packaging segments, are the following market drivers:

1. Technology Shift: A technology shift from hot stamp printing to thermal transfer is underway in the manufacturing sector. There are approximately 90,000 hot stamp printers in the US focused on flexible packaging applications. Over the next five years a 40 percent to 50 percent conversion rate from hot stamp printing to thermal transfer printing is expected. This transition is creating market opportunities for equipment, media and thermal transfer ribbon (TTR) manufacturers.
2. Manufacturing cost reductions: Thermal transfer printing offers several benefits in manufacturing over the hot stamp method. The benefits that provide the most economic advantage to manufacturers are: 1.) Shorter set up times, 2.) No tooling requirements, and 3.) Less down time. All three benefits provide savings in manufacturing through improved manufacturing efficiency and a lower cost of ownership.
3. Governmental regulations: The Food and Drug Administration (FDA) has approved the Bar Code Label Requirements for Human Drug Products and Biological Products . The FDA's goal is to reduce medication errors by bar coding prescription drugs and certain over the counter (OTC) drugs and utilize these bar codes in conjunction with a bar code scanning system and database. This initiative will drive the need for bar code printing variable information using thermal transfer printing technologies.
4. Real time data: Increasing quality control requirements have been driving the need for real time data in manufacturing. Data, such as manufacturing date, time, year, operator, shift, serialization, product category, and part number are becoming standard printing requirements in the world of flexible packaging. This is allowing manufacturing facilities to streamline their supply chains, improve in-house quality control, and meet government mandated traceability standards.

Benefits:
Ink jet and hot stamp are two of the more popular printing processes found in the manufacturing process. Thermal transfer offers several key benefits in manufacturing over traditional ink jet and hot stamp printing methods.

Set Up Costs:

Tooling Issues - the hot stamp printing process has considerably more tooling requirements than thermal transfer.

Cleaning Procedures - ink jet has very detailed maintenance procedures for cleaning the system to ensure print quality and system longevity.

Product Line Changeover - thermal transfer provides the least demanding process during product changeover on the manufacturing line.

Cost of Ownership:

Tooling Requirements - each product line is often dependent on a dedicated set of tooling. This tooling must also be managed and maintained.

Costly preventative maintenance procedures are required with ink jet and hot stamp printing compared to thermal transfer printing systems.

In process cleaning procedures are very costly especially with ink jet systems.

Training:

Hot stamp and ink jet both require extensive training procedures and time before and operator is fully educated.

Efficiency:

Thermal transfer print technology improves the time required for product changeover. By requiring less down time during production, a lower operating cost and lower throughput time can be expected.

Decision Makers
Unlike bar code applications, which primarily involve purchasing and logistics personnel, flexible packaging applications involve people dedicated to Work In Process (WIP). Below is a list of personnel involved with a company's WIP:

Packaging Engineers
Packaging Specialists
Facilities Planning/Management
Facilities Engineer
Industrial Engineer
Manufacturing Engineer (Processing Engineer)
Product Engineer
Manufacturing Manager/Supervisor
Director of Engineering
Engineering Manager
Director of Quality
Quality Manager
Quality Engineer

Industry News and Markets | Presentation

Applications and Product Information: Labels, Printers, and Products

DNP's Thermal Transfer Ribbons for Flexible Packaging
DNP has an extensive line of thermal transfer ribbons for flexible packaging applications, available in wax, wax/resin, and resin, for both flat head and near edge printers.

Flat Head Flexible Packaging Thermal Transfer Ribbons
The following ribbons are recommended for flexible packaging applications where the printer or print engine has a flat (conventional) print head:

Near Edge Flexible Packaging Thermal Transfer Ribbons
The following ribbons are recommended for flexible packaging applications where the printer or print engine has a near edge print head:

Printers, Coders and Over-printers for Flexible Packaging
The basic characteristics of thermal transfer printing are highly compatible with flexible packaging printing. Lot code, manufacturing date, pricing and product description can all be printed during the packaging process. This basic manufacturing information must always be revised and is best served by a technology that can be used for direct printing variable information, on demand.

Near Edge Flexible Packaging Printing
Using near edge ribbons and printers to print on flexible packaging materials gives the following advantages:

High print speeds: Print speeds of 20 inches per second are now not uncommon. Higher print speeds mean that an in-line printer can now keep up with a high speed production line.

Variable substrate thickness: Thicker flexible films, which cause many problems to the fixed print heads of flat head machines, are easily accomodated by the floating print heads of near edge inline printers.

Wider variety of printable substrates: In contrast to flat head, near edge thermal transfer ribbons are not limited to printing only on surfaces specifically prepared for thermal transfer. In particular, pre-printed packaging films make good print surfaces for DNP's near edge flexible packaging ribbons.

Some of the best-known near edge flexible packaging printer manufactures are:

Markem Corporation - Manufacturers of the popular Smart Date series of printers. The installed base of these printers is around 30,000 units. Markem claims that one of its latest machines, the Smart Date 5s, can print at speeds in excess of 70 inches per second.
Norwood Marking Systems - Manufacturers of the Jaguar and Thermapack printers. Although recent printers have all been near edge, there remains a substantial base of earlier generation flat head Jaguar printers.
Videojet - Videojet's Dataflex machine features a bi-directional ribbon drive, which is used during regular printing to maximize ribbon economy, but can also be used to switch the printer from right-hand to left-hand operation.
Bell Mark - Manufacturers of the Easy Print series of printers. "Ribbon Save" feature can alter synchronization of ribbon and substrate advance, leading to a less dense printed image but greater ribbon economy.
Open Date - Unlike other printers described here, which need a compressed air supply to operate, the Open Date is completely electronic.

Flat Head Flexible Packaging Printing
Flat head printers are preferred over near edge printers when higher durability is required. Flat head is also still preferred when in-line marking is needed for bagging machines, pouching equipment, shrink wrapping machines, and others. There are many companies involved in the manufacturing of such equipment; the best known of these is Autobagger (also known as APS or Advanced Packaging Systems). However, the printers installed in these units are manufactured by companies from the flat head desk top market - Sato, Zebra, and Datamax . (Sato has approximately 70% of the market.) The common practice is to give customers a choice in specifying their own machine, including choice of print engine.

Substrates for Flexible Packaging
The major manufacturers of flexible packaging films include:

Alcoa - A comprehensive range of films for packaging, including polyethylene and polypropylene, shrink films and shrink sleaves.

Chevron Philips - Emphasis is on polyethylene and styrenic polymers,

ExxonMobil - Wide range of OPP's and polyethylenes.

Direct near edge printing on these films is best accomplished by DNP's M295 ribbons, which are available in black, white, and silver.

Testing has shown very good results for bagging machines with DNP's W160. DNP has also done extensive testing with in-line flat head film printing, and recommends M265 for these applications. DNP's R300 ribbon has seen success in printing on coated aluminum foils.

Another major flexible packaging growth area is in medical device packaging. Materials for this application must be strong and tear-resistant, breathable enough to allow the penetration of steam, ethylene oxide or other sterilization agent after packaging, but also resistant to microbial (bacteria, spores and other contaminating microorganisms) penetration. These demands are met by three varieties of DuPont's Tyvek - 1073B, 1059B, and 2FS. W190 produces good results on these Tyveks and is recommended for all near edge medical applications.

DuPont Tyvek

The medical grade Tyveks, however, are losing market share for packaging medical devices to a new generation of medical grade papers. The market, which was a few years ago split 70:30 in favor of Tyvek, is now roughly 50:50. Again, among DNP's products, W190 is the clear choice. Links to two of the major manufacturers of medical grade papers are given below:

Bomarko, Inc.

Neenah Paper, Inc. (formerly Kimberly-Clark Technical Paper)

Flexible Packaging Marking Applications
Near edge printers are able to print on an extremely wide range of substrates. This has helped thermal transfer make inroads into many different applications and markets. Ease of use, especially in the easy revision of variable data printed on packages, has further promoted growth in many markets. Some of the recent increases in thermal transfer flexible packaging printing have been in:

• Consumer Goods:
  • Snack food date and lot stamp marking has seen large growth in recent years.
    
  • Meats, cheeses, frozen food and beverages are increasingly marked with lot number and "best by" dates.
    
  • Condiments often have date and lot printed on a small label attached to the container.
    
  • Cosmetics such as perfume and lipstick are often packaged in chipboard boxes onto which date, manufacturer and lot code can be thermal transfer printed.
• Medical and Pharmeceutical:
  
  • Medical Devices are packaged in Tyvek or medical grade paper, both of which are thermal transfer printable.
    
  • Pharmeceuticals have lot and date codes printed - from the label of a pill bottle to the lidding of blister packs - by thermal transfer.
    
  • Over-the-Counter Prescriptions have increasingly complex sets of information on their labels in a move to prevent prescription errors - patient name and dosage information, the National Drug Code, and more. Some of this information is also reproduced in a RSS bar code.
    

A full list of recommended DNP ribbons and applications is shown below.

Industry News and Markets | Labels, Printers and Product

Technical White Papers and FAQ's: Understanding Flexible Packaging Printing with TTR

Click here to see a presentation that can be used to educate prospective customers on all aspects of flexible packaging printing with thermal transfer ribbons.

DNP Secure Printing Technologies: Hologram and UV

Labels, Printers and Product | FAQ's | Testimonials

Industry News and Markets: Security-Holograms and UV

State of the Market
The global counterfeiting business has grown tremendously over the last five years. Automotive parts, medical equipment, computer chips, pharmaceutical products, batteries, print cartridges, financial documents, and government records are just a few of the items actively counterfeited and circulating the globe. GM, HP, Black and Decker, Ping, BP (oil), Honda, Toyota, Callaway, IBM, and Pfizer, just to name a few, have all been victims of counterfeiting.

According to BusinessWeek, the World Customs Organization estimates that counterfeiting accounts for 5 percent to 7 percent of global merchandise trade, which equates to approximately $512 billion, 2004 estimate. Domestically, counterfeiting costs US retailers $250 billion per year with no end in sight. Last year alone seizures of fakes by US Customs jumped 46 percent as counterfeiters boosted exports to Western markets. According to the World Health Organization, 10 percent of medicines worldwide are counterfeited; ultimately, costing the pharmaceutical industry $46 billion a year. Seizures of fraudulent car parts have been estimated to cause $12 billion per year in losses to the global automotive market (Fakes! Business Week, Feb. 2005). The level of threat experienced by these organizations has prompted many of them to develop internal departments with the charter to oversee brand protection and security efforts. Part of this effort focuses on finding products and services to interface with their systems, products, and documents to provide levels of security against counterfeiting. In the wake of these issues, holograms and ultraviolet sensitive inks (UV) have become well established and accepted as effective security and authentication devices.

Holograms and UV Defined
Holograms and UV are optical devices used throughout the security and brand protection market segments. They cannot be replicated with current printing techniques, color copiers, or specialized computer equipment (easily purchased by the public sector). They are also a widely accepted device for providing various levels of security to a product or document.

Hologram - the hologram belongs to a class of images known as Diffractive Optical Variable Image Device (DOVID). It is a unique photographic printing that provides a two- or three-dimensional effect on a flat surface. They cannot be easily copied and are used for security and aesthetic applications.

Ultraviolet Ink - ultraviolet inks are materials that will fluoresce under ultraviolet light producing colors or light that our eyes can see. The ink remains invisible to the eye when not exposed to an ultraviolet light source.

Hologram Current and Projected Global Sales
Global sales of holograms reached $1.09 billion in 2001. The use of holograms has grown tremendously over the last five years, primarily in two areas:

1. Secured Documents - banknotes, tax documents, and identity documents.
2. Brand Protection - manufactured items.

NOTE: Although packaging represents the largest volume for holograms, security-printing applications represent the largest dollar volume.

By market percentage of major applications, security printing retains 41 percent and brand protection retains 20 percent. These two areas have remained the largest single markets for holograms. Forecasters have projected a continued double-digit growth into 2007 where it will begin to taper to single digit numbers. In 2007, global industry sales are projected to be between $1.8 billion and $2.15 billion (Holopack-Holoprint Industry Survey & Market Report: 2001-2007, Reconnaissance International 2002).

End Users
DNP's hologram and UV security products have been developed to support the business owner that requires an affordable, less sophisticated security solution. They are typically business owners whose products range from special event tickets and government documents to collectibles. They typically battle the "casual counterfeiter" - someone using fairly unsophisticated technology (a computer or scanner) that can be purchased in a retail outlet.

DNP's Secure Printing Technology
Among DNP's 50 different security printing technologies, hologram and UV security devices are resin-based products developed for the thermal transfer printing technology (flathead printing technology). These products are capable of printing on-demand, variable information in real time. It is an affordable solution to the small to medium business owner's security and brand protection applications.

For more details concerning performance and product applications call the Product and Services Department at 1-800 814-4672, press option 3.

Security Markets, Holograms and UV | FAQ's | Testimonials

Applications and Product Information: Labels, Printers, and Products

DNP Hologram and Ultraviolet (UV) Thermal Transfer Ribbons are both resin-based, high durability security products that can be printed with any regular flat head thermal transfer printer.

Hologram Thermal Transfer Ribbon Construction
The hologram ribbons are manufactured in a variety of patterns, all of which can be printed onto standard polyester or polypropylene thermal transfer labels or PVC cards to produce a fully-functional DOVID (Diffractive Optically Variable Image Device). Most of DNP's hologram ribbons are created by splitting a beam of laser light in two, and aiming one of the beams at a photo-sensitive receiver. The other beam is reflected off the object that will appear in the finished hologram, and then scattered onto the same photo-sensitive receiver. For some smaller, more intricate designs, DNP will substitute an electron beam for laser light. In both cases, the receiver is a sheet of glass covered with a photo-sensitive coating. After exposure, the coating is cured. A UV-curable layer of resin is then applied to the glass sheet and cured coating, creating a mirror image of the exposed glass. The resin layer is cured and then removed from the glass as a flexible sheet. In this form, it is flexible enough to be curved around a printing cylinder in the next stage of the manufacturing process, and strong enough to emboss another material as part of that process. (It is also a sufficiently low-cost intermediate component of the process to be routinely destroyed after the hologram ribbon has been created, thus ensuring the security of the final design.)

The next stage of the process is to construct the final ribbon configuration. Coated layers are applied to a PET film carrier in a similar way to a standard DNP thermal transfer ribbon. A heat resistant layer is applied to the side of the ribbon that contacts the print head to ensure good heat conductivity and low-friction passage of the ribbon across the print head. On the other side of the film a release layer is added, to aid adhesion of the subsequent layers to the PET and ensure clean release of those layers during the printing process. The next layer is a UV-curable resin. This resin is soft enough to be embossed, and rigid enough to retain the embossed pattern. At this point in the process the resin sheet, created earlier, is wrapped around a print cylinder, and the resin-coated film is fed between this cylinder and a pressure roller to emboss the holographic image.

The embossed resin is now UV-cured, not only to secure the holographic image but also to prepare it for the next phase of the process, metallizing. Metallizing is a process to create the "mirror" effect of the hologram. During the process, aluminum is sputtered onto the embossed resin at a temperature of approximately 1300°F. After metallizing, a heat activated adhesive layer is added to the ribbon.

UV Thermal Transfer Ribbon Construction
The design and production processes behind the UV ribbon are much simpler than the hologram, and is similar to a standard black ink thermal transfer ribbon. A heat resistant layer is applied to the side of the ribbon that contacts the print head to ensure good heat conductivity and low-friction passage of the ribbon across the print head. On the other side of the film, a release layer is added to aid adhesion of the subsequent layers to the PET and ensure clean release of those layers during the printing process. Finally, a layer of UV ink is coated on top of the release layer. This ink adheres directly to the print surface - there is no need for an adhesive layer.

When printed onto a substrate, the UV ink is transparent. However, when brought close to a UV light source, the image will fluoresce (emit light) with a strong purple color. Like most fluorescent materials, the useful life of images printed with DNP's UV ribbons is a function of the time and intensity of exposure to other UV light sources (e.g. sunlight). However, as seen in Figure 1, even after 1 ½ years of exposure to sunlight, fluorescence will still be at 50% of its original value. Indoors, without intense UV light (sulight) exposure, the light fastness of the ribbon is practically unlimited.

Figure 1: Light stability of DNP UV Ribbon

Performance Characteristics
DNP hologram and UV thermal transfer ribbons have performance characteristics very similar to the black ink resin ribbons of DNP's core product line.

Figure 2: Abrasion Resistance of TTR Hologram Ribbons

Abrasion resistance of the hologram ribbon lies midway between R510 (Ultra Durable Resin Ribbon) and R300, which is DNP's general purpose resin ribbon (Figure 2). By comparison, overall durability of the UV ribbon, while still high, falls between DNP's R300 and R316 (Specialty Resin) ribbons (see Figure 3).

Figure 3: Abrasion Resistance of TTR UV Ribbons

The hologram ribbons have chemical resistance similar to DNP's R510 ultra-durable resin ribbon, as seen in Figure 4.

Figure 4: Solvent Resistance of TTR Hologram Ribbons

Chemical resistance for the UV ribbon is equal or less than the chemical resistance of R316 (Figure 5).