CIJ vs. TIJ

• Both CIJ and TIJ are well proven marking and coding technologies and can handle marking applications across a diverse set of industries.
• From a cost of ownership standpoint, TIJ printers are far more cost effective. In fact a major paper manufacturer saved over $100,000 in upfront costs alone by switching to a low-cost VIApack solution from Matthews.
• For applications that require higher resolution marks such as 2D codes and traditional 1D barcodes, TIJ is the superior option.

From the minute a product enters the production line to the time it leaves the manufacturing facility, it likely has gone through multiple marking events. From barcodes and sell-by dates to carton codes and pallet labels, there are myriad ways that products and packaging are marked for identification, tracking and traceability. Each mark comes with its own set of challenges based on the product, as well as the shape, the size and the material of the item to be printed on. So, the trick for manufacturers is understanding what print technology will be most efficient and reliable for each stage of the process.

The very common industrial print technologies on the market are continuous inkjet (CIJ) and thermal inkjet (TIJ), both of which come with pros and cons and best use-case scenarios. Below we break down the difference between these two technologies and the ideal scenarios for using each.

The basics: How do CIJ and TIJ work?

CIJ has been the dominant solution for small character primary marking for many years. As you can likely tell from the name, CIJ printers use a high-pressure nozzle to spray a continuous stream of ink droplets from the printheads single nozzle, most of which end up in the printhead’s gutter and returned to the ink supply. These droplets may or may not be charged by electrodes and able to be “steered” to create the text or images.  When needed, those droplets that are charged are forced through the printing system and used to form the mark. Those that are not charged fall into the gutter and back into the system.

TIJ on the other hand is a “drop on demand” style of printing, using heat to transfer ink and pigments to the desired product, carton or label. The ink stays static until it’s needed, at which point the droplets are rapidly heated and vaporized by a resistor coil, and then ejected from the chamber via pressurized air bubbles (formed from the vaporization) to form a mark, code or image

Industrial TIJ printers such as the Matthews L-Series, shown here in a turnkey ViaPack configuration, can easily be added to any production line and support a wide range of high-resolution marking applications.

Weighing the pros and cons of CIJ and TIJ

With the above in mind, let’s dig into the advantages that CIJ and TIJ bring to the table, as well as some of the downsides. To help illustrate this clearly, we’ve created a chart for both the pros and cons, demonstrating what benefits you would get with each print technology followed by the disadvantages to using each for marking.

Advantages and Disadvantages of CIJ

Advantages

• Throw Distance Flexibility: CIJ printers do not need to come in contact with a product for printing and can be placed a reasonable distance away. This allows for better marking on fragile or oddly shaped products, such as curved products or those that may shift or bounce on the production line.
• Less Risk of Clogging: With a continuous stream of ink, there is a reduced opportunity for the nozzles to clog and disrupt printing. However, challenging environments that produce dust or other residue, such as wood or flour bag marking, can still cause debris buildup in the system.
• Availability of Parts: Because CIJ printers have historically been more widely used than TIJ printers, the materials and parts needed to keep them running are generally accessible and available at competitive prices. Newer CIJ systems may also use replaceable modules that require less maintenance.
• Multiple Ink Options: CIJ printers can work with everyday all-purpose inks as well as specialty inks. This makes CIJ suitable for a broad range of applications, industries, packaging cartons, labels, and other materials.

Disadvantages

• Lower Image Resolution: CIJ printers produce lower-resolution dot patterns that may not be ideal for more complex codes or images, especially as marking requirements evolve to include more data and improved traceability. The maximum resolution for CIJ printers is typically around 31 dpi.
• Durability and Reliability: Ink from CIJ printers can be more prone to smudging, running, or staining, particularly when products are exposed to changing environmental conditions after leaving the warehouse.
• Increased Cleaning: Because of the continuous spray and circulation of ink, the floor or work area around a CIJ printer can become coated in ink. This may require specialized cleaning and, depending on the application, additional ventilation.
• Maintenance of Printers and Parts: CIJ printers have more components than TIJ systems, creating more opportunities for wear or breakage. Repairs may require the entire printer to be taken offline, while annual maintenance can contribute to higher long-term operating costs.
• Startup Time: CIJ coders can take several minutes to start up before printing can begin. This can result in lost operator time and unnecessary production downtime at the start of shifts or following a stoppage.

Advantages and Disadvantages of TIJ

Advantages

• High Image Resolution: TIJ printers can print at resolutions up to 600 × 600 dpi, producing crisp, high-quality marks. This makes TIJ a strong option for GS1-compliant barcodes and other detailed codes used in medical, pharmaceutical, and other traceability-focused applications.
• Durability: TIJ printers can produce durable marks capable of withstanding a range of environmental conditions, including cold storage.
• Fewer Spills: The cartridge-based design of TIJ printers reduces the risk of spills compared with CIJ systems. Overall, this can mean less cleanup and less regular maintenance.
• Cleaner Operation: Advances in TIJ technology have reduced ink and debris buildup that can lead to clogging. Some systems also include automated printhead cleaning or spitting functions.
• Fewer Parts: TIJ printers have fewer moving parts, reducing the number of components that can fail. Individual parts can often be replaced without taking the entire system offline.
• Reduced Maintenance Costs: TIJ printers generally require less ongoing maintenance than CIJ systems. Routine maintenance is largely centered around cartridge replacement, which can typically be handled without specialized technical support.
• Versatility: TIJ printers can print on a wide variety of surfaces, including porous materials. Their smaller printheads also make it easier to print in confined or hard-to-reach areas.
• Small Footprint: TIJ systems are typically more compact than CIJ printers, making them easier to integrate into production lines where space is limited.

Disadvantages

• Limited Throw Distance: Compared with CIJ printers, TIJ printheads generally need to be positioned within a few millimeters of the product to create an accurate mark. Products also need to move smoothly past the printhead. Longer-throw TIJ technologies are beginning to address this limitation.
• Fewer Ink Options: TIJ technology can offer fewer ink options depending on the application and substrate. Certain materials may require specialized inks, which can increase operating costs.
• Cartridge Costs: Although TIJ systems generally have lower overall maintenance costs, replacement cartridges can cost more than some individual CIJ replacement parts. However, TIJ systems typically require less labor and maintenance overall.
• Cannot Print Upward: Because of the way TIJ printers produce ink droplets, they are generally not suitable for printing upward onto the bottom of a product, such as the underside of a can or bottle. This is less of an issue for secondary packaging, which is usually marked on the side or top.

Determining when to use CIJ vs. TIJ

As laid out above, there are pros and cons to both print technologies. So now, armed with the knowledge of what CIJs and TIJs do and the advantages of both, you might be wondering – which one works best for my application?

While we can’t definitively give you an answer, we can help guide you by providing some general use case scenarios for each:

• CIJ: If you’re printing marks and codes with a fast, continuous production process that utilizes a significant amount of ink (e.g., expiration dates on food packaging), CIJ might be a good fit. This is especially true if you run a production line that operates 24/7 and won’t be impacted by slow startups. In addition, as mentioned above, CIJ printers have more throw distance flexibility, allowing them to print from a distance, over curved or rough surfaces, and/or with products that don’t move smoothly through the production line.
• TIJ: If you need a high-resolution mark, such as for a GS1 compliant barcode, then TIJ is the best print technology to use. In addition, because you can easily swap out the ink cartridges, TIJ is also a great solution if you need to move seamlessly between ink types or colors. And finally, the instant startup and small footprint of a TIJ can’t be beat. So, if you need a small, reliable printer to fit in compact spaces or need larger marks, you’ll definitely want to consider TIJ.

Example of a CIJ printer suitable for industrial applications such as low-resolution coding on primary packaging.

TIJ cuts capital expense for paper manufacturer by $100,000

A major producer of cut and wrapped fine paper products based in the Midwest, faced significant challenges with its outdated marking systems. The legacy equipment was bulky, messy, disliked by the operators and error prone, not to mention expensive to maintain.

Seeking a modern and cost-effective solution, the paper company turned to Crown Packaging Corporation, which recommended Matthews Marking Systems VIApack, an affordable thermal inkjet printer and controller bundle. Despite initial skepticism, a successful trial proved the L-Series printers‘ superior quality, ease of use, and cost efficiency when compared to CIJ alternatives.

The mill transitioned seamlessly to the new technology, installing eighteen VIApacks with remarkable speed and minimal disruption. The results were impressive: improved print quality, reduced errors and downtime, and substantial up-front cost savings of well over $100,000.

Thermal Inkjet, Simplified for Today’s Production Lines

Today, advancements in thermal inkjet technology continue to build on these benefits. Systems like the CT1000 thermal inkjet printer are designed for fast deployment and reliable performance in production environments. With a compact, all-in-one design, quick setup, and minimal maintenance requirements, the CT1000 delivers high-quality codes on both porous and non-porous surfaces while reducing complexity and operator involvement.

Side by side for the win

If you read the above and thought “I need all of that for my production line!” you’re not alone. There may be one part of your production line that would be best served by CIJ, whereas TIJ would work best for another. Matthews Marking System’s MPERIA platform is the best printer controller technology for this scenario as it can support different printing technologies from one controller. For example, you might need to mark bottles with a CIJ but use a Matthews L-Series TIJ for direct carton marking. With the MPERIA system you can centralize your production operations and simultaneously control all your print technologies from one screen, ultimately increasing productivity and efficiency.

Interested in a demo of how MPERIA can help you support both CIJ and TIJ (and any other print technology) on your production lines? Give us a call at ​​800.775.7775 or email us at [email protected].