Introduction
Industrial manufacturing and packaging require precise product identification, traceability and compliance to meet regulatory standards and enhance supply chain efficiency. Selecting the right coding, marking or labeling technology depends on substrate type, print durability, resolution, cost effectiveness and maintenance needs.
This white paper provides an in-depth technical comparison of the following technologies:
- Thermal Inkjet (TIJ) – Norwix, Squid Ink
- Continuous Inkjet (CIJ) – LEIBINGER, Squid Ink
- Drop-on-Demand (DOD)/Piezo – Squid Ink (including CoPilot series)
- Laser Marking – Squid Ink
- UV LED Curing – Squid Ink
- Print-and-Apply Labeling – NITA, Label-Aire and Videojet
Each method is evaluated based on its technical specifications, ideal applications, advantages and limitations, followed by a comprehensive comparison matrix for quick reference.
1. Direct-to-Product Coding & Marking Technologies
1.1 Thermal Inkjet (TIJ) – Norwix, Squid Ink
How It Works
Thermal Inkjet (TIJ) technology uses micro-resistor heating elements that generate heat pulses to vaporize ink, creating expansion that forces droplets through microscopic nozzles onto the substrate. The process allows high-resolution characters and barcodes with sharp contrast.
Technical Specifications
- Print Resolution: Up to 600 dpi
- Print Speed: Up to 100 meters per minute
- Ink Types: Water-based, solvent-based, UV-curable inks
- Drop Volume: 1–10 picoliters, enabling fine detail printing
- Nozzle Diameter: 10–30 µm
- Maintenance: Minimal, printhead is replaced with each cartridge
Best Applications
- High-resolution carton coding for food, beverage and industrial goods
- Pharmaceutical and medical packaging requiring traceability
- Logistics and warehousing (sharp, scannable barcodes)
Advantages
- High-resolution printing for barcodes and small text
- Low maintenance, printhead is integrated into each cartridge
- Compact and modular, easily integrates into packaging lines
Disadvantages
- Higher ink cost per print due to cartridge-based system
- Lower speed compared to CIJ in very high-volume applications
- Limited adhesion on non-porous surfaces without specialized inks
1.2 Continuous Inkjet (CIJ) – LEIBINGER, Squid Ink
How It Works
CIJ printers generate a continuous stream of electrically charged ink droplets by applying a high-frequency pulse to a pressurized ink flow. Charged droplets are deflected by electrostatic plates, directing them onto the substrate, while unused ink is recirculated.
Technical Specifications
- Print Resolution: 60–300 dpi
- Print Speed: Over 300 meters per minute
- Ink Types: Solvent-based, MEK-based, pigmented inks
- Nozzle Diameter: 40–70 µm
- Ink Recovery System: LEIBINGER Sealtronic prevents nozzle drying
Best Applications
- Beverage and food packaging (bottles, cans, flexible packaging)
- Extrusion marking (cables, pipes and automotive parts)
- Pharmaceutical compliance coding (expiration dates, batch numbers)
Advantages
- High-speed printing, even on irregular and curved surfaces
- Compatible with non-porous substrates (glass, plastic, metal)
- Self-cleaning printheads with LEIBINGER Sealtronic technology
Disadvantages
- Requires solvent-based ink management
- Lower resolution than TIJ, not ideal for high-detail barcodes
- Higher maintenance requirements due to ink recirculation
1.3 Drop-on-Demand (DOD)/Piezo – Squid Ink
How It Works
DOD piezo printers use electrically activated piezoelectric crystals to flex and eject ink droplets only when needed. This allows very large character sizes, high throw distances and the ability to mark directly on cases and secondary packaging with bold, readable codes.
Technical Specifications
- Print Resolution: Up to 360 dpi
- Print Height: From a few millimeters up to several inches
- Ink Types: Oil-based, solvent-based and pigmented inks
- Throw Distance: Up to ½ inch for uneven or rough surfaces
- Maintenance: Low, no recirculating pumps required
Best Applications
- Case coding on corrugated packaging
- Pallet marking with large, scannable characters
- Wood, gypsum board, textiles and building materials
Advantages
- Large character codes visible from long distances
- Rugged printers with long service life
- Wide substrate compatibility with pigmented and oil-based inks
Disadvantages
- Lower resolution than TIJ or UV LED systems
- Not suitable for small barcodes or fine detail
High-Resolution CoPilot Series
Squid Ink’s CoPilot printers represent the next step in piezo technology, delivering mid- to high-resolution printing (180–360 dpi). These systems produce sharp barcodes, logos and text for secondary packaging and graphics. With oil- and solvent-based inks, they are a versatile bridge between large-character case coding and fine-detail TIJ or UV applications.
1.4 Laser Marking – Squid Ink
How It Works
Laser marking modifies the surface using a focused, high-intensity laser beam, which vaporizes, ablates or induces a chemical color change to create permanent marks.
Technical Specifications
- Laser Types: CO₂, Fiber, UV
- Marking Speed: Up to 2,000 characters per second
- Resolution: Up to 1,000 dpi
- Substrates: Metals, plastics, glass, ceramics
- Maintenance: Minimal, as no consumables are needed
Best Applications
- Automotive, aerospace and medical device part marking
- Counterfeit prevention in high-value products
- Food and beverage permanent date coding on glass bottles
Advantages
- Permanent, tamper-proof markings
- No ink, solvents or consumables
- High-speed, non-contact operation
Disadvantages
- High initial investment
- Not suitable for heat-sensitive substrates
- Requires fume extraction when used on plastics
1.5 UV LED Curing – Squid Ink
How It Works
UV LED curing instantly cures UV-reactive ink upon exposure to ultraviolet light, resulting in immediate bonding to non-porous surfaces.
Technical Specifications
- Print Resolution: Up to 1,200 dpi
- Print Speed: Up to 200 meters per minute
- Ink Type: UV-curable ink
- Substrates: Coated cartons, plastic, flexible packaging and glass
- Maintenance: Minimal, UV ink does not dry in the printhead
Best Applications
- Luxury packaging and cosmetics
- Food-grade applications with low-migration inks
- Durable branding on plastics and glass
Advantages
- Immediate drying with high contrast
- Superior adhesion on non-porous surfaces
- Eco-friendly with low VOCs
Disadvantages
- Higher cost of UV-curable inks
- Requires UV LED curing lamps
- Limited to UV-reactive materials
2. Print-and-Apply Labeling – NITA, Label-Aire, Videojet
Print-and-apply systems combine thermal transfer or direct thermal printing with an automated applicator that places labels directly onto products, cases or pallets.
- NITA and Label-Aire use SATO and Zebra print engines, long-established in the market for reliable, high-resolution printing of barcodes and variable data.
- Videojet’s latest print-and-apply systems feature a fully built-in proprietary print engine. This design integrates the print module more tightly with the applicator hardware, reducing dependency on third-party components.
Technical Specifications
- Print Resolution: Up to 600 dpi
- Print Speed: Up to 40 labels per minute (standard), higher for tamp-blow or corner wrap systems
- Substrates: Applicable to any material via label stock
- Consumables: Labels and ribbons
- Maintenance: Low, routine replacement of printheads and wear parts
Best Applications
- Case labeling for warehousing and distribution
- Pallet labeling with GS1 and UCC compliance
- Food and beverage product labeling with barcodes and nutrition facts
- RFID-enabled smart labeling for pharma, medical and logistics
Advantages
- Flexible, applies labels to any surface
- High print quality with scannable barcodes
- Easy to update information for variable data
- RFID encoding capability for smart supply chain applications
Disadvantages
- Requires label and ribbon inventory
- Slower throughput compared to direct coding technologies
- Mechanical wear of applicators over time
2.1 Print Engine Comparison: Videojet vs SATO/Zebra
- SATO and Zebra engines (NITA, Label-Aire): Proven reliability, widespread adoption and easy access to replacement parts and consumables. Standardized, making them familiar for operators. Dependence on third-party suppliers can limit flexibility.
- Videojet proprietary engine: Tightly integrated with applicator hardware, optimized for serviceability and control. Eliminates compatibility issues with third-party engines but may reduce cross-compatibility with other label applicator systems.
3. Technology Comparison Matrix
| Factor | TIJ | CIJ | DOD/Piezo (incl. CoPilot) | Laser | UV LED | Print-and-Apply |
|---|---|---|---|---|---|---|
| Print Resolution | Up to 600 dpi | 60–300 dpi | Up to 360 dpi | Up to 1,000 dpi | Up to 1,200 dpi | Up to 600 dpi |
| Print Speed | Moderate | High | Moderate | High | High | Moderate |
| Substrates | Porous and semi-porous | Porous and non-porous | Porous, rough and coated | Metal, plastic, glass | Glossy and non-porous | Any material (labels) |
| Consumables | Ink cartridges | Ink and solvents | Bulk inks | None | UV-curable ink | Labels and ribbons |
| Maintenance | Low | Moderate | Low | None | Low | Low (printhead wear) |
| Cost | Low upfront | Higher upfront | Moderate | High upfront | Higher upfront | Moderate |
4. Conclusion: Expert Solutions from Pacific Labeling & Integration
Choosing the right coding, marking or labeling technology is critical to ensuring production efficiency, regulatory compliance and long-term cost effectiveness. Each method has its own strengths and trade-offs, making it essential to work with experts who understand both the technical specifications and real-world applications of these solutions.
At Pacific Labeling & Integration, we provide comprehensive, end-to-end solutions tailored to your operation’s needs. We also supply all related consumables including inks, solvents, ribbons and labels to ensure your systems run without interruption. As the exclusive West Coast service center and distributor for LEIBINGER, Squid Ink, NITA, Label-Aire and Norwix, we offer unmatched expertise, local responsiveness and factory-trained technicians who keep production moving.
With decades of experience in industrial marking, coding and labeling, Pacific Labeling & Integration is your trusted partner in achieving consistent, high quality product identification and traceability. Whether you need a high-speed marking system for a demanding production line, a mid-resolution piezo solution like the CoPilot series, or a precisely engineered labeling system with RFID smart label capability, we are committed to delivering unmatched reliability, service and expertise.
Sustainability is also an increasing priority. PLI supports eco-conscious manufacturing with water-based TIJ inks, UV LED low-VOC systems and label materials designed for recycling and reduced environmental impact.
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