ESMA Academy: Inkjet know-how for the plastics industry

The digital printing of plastics opens up numerous possibilities for individualization, efficiency and sustainability. But what technical requirements need to be met? Which materials are particularly suitable? And how can companies make the most of the potential of inkjet technology? Answers to these questions are provided by the ESMA Academy, a training platform for professionals involved in industrial printing processes.

In an interview with K-Mag, Oliver Kammann from K-Flow Consulting GmbH talks about the content of the Academy, who it is suitable for and why in-depth knowledge of printing technologies is becoming increasingly important in the plastics industry.

What are the advantages of inkjet technology compared to traditional decoration processes, especially for plastics?

Oliver Kammann: Inkjet technology offers several advantages. It is a contactless printing process, allowing for variable data and different images on each pass. All colors are printed in a single step without re-registering, improving efficiency.

The use of UV LED inks ensures fast and economical curing, with other options like e-beam available. Inkjet also eliminates the need for labels, screens, and printing cylinders, reducing stock requirements. It supports flexible and rigid plastics, including post-forming applications, and enables embossing, frosting, and other effects. Additionally, it is cost-effective for both short and large production runs.

Which types of plastic substrates are particularly suitable for inkjet decoration and why?

Kammann: The suitability of plastic substrates for inkjet decoration depends on proper surface preparation to ensure optimal ink adherence and image quality. The surface must be in good condition to create a strong bond and minimize ink spread. Some inks are specifically formulated for certain plastics to enhance adhesion.

Generally, PET, ABS, PP, HDPE, and PE provide the easiest results. PVC and acrylic can also be used but may require more careful testing to achieve the best outcome. Proper pre-treatment is key to ensuring high-quality prints on any plastic substrate.

What opportunities does inkjet offer for product personalization and differentiation?

Kammann: With inkjet each image can be unique, whether entirely or in specific parts. It enables variable data and image printing, serialization, and customization with ease.

Inkjet allows for the application of embossing, structural effects, and matte or glossy lacquers, adding depth and texture to designs. It also supports security printing and product tracing through special inks or hidden codes created by adjusting drop placement. Barcodes and other tracking codes can be printed on demand, enhancing functionality and security.

What specific topics and skills are taught at the ESMA Academy?

Kammann: The ESMA Academy is designed for professionals with a basic understanding of inkjet technology, offering in-depth training tailored to specific applications such as plastics, glass, textiles, and functional printing. Each course combines theoretical lessons with practical sessions, covering both general principles and application-specific content.

Key topics include ink chemistry, printhead physics, surface pre-treatment, adhesion, and color management. Participants also learn about print defects, ink characterization, waveform optimization, and drying techniques such as UV, IR, and eBeam. Additionally, the program explores ink formulation, filtration, supply systems, and emerging market trends. A strong focus is placed on problem-solving, allowing attendees to engage in open discussions and hands-on fine-tuning of their printing systems.

Who is the Academy aimed at and what prior knowledge should participants have?

Kammann: Our course is designed for a broad audience, including companies developing inkjet systems, print service providers integrating inkjet into their operations, and end-users or brand owners seeking a deeper technical understanding beyond supplier marketing.

Brands, in particular, benefit from learning how to maximize inkjet technology while avoiding design and decoration pitfalls. New industries, such as plastic profiles in the building sector and vinyl flooring manufacturers, are exploring inkjet to enhance efficiency, expand their product offerings, and adopt more sustainable production methods. Participants should have a basic understanding of inkjet technology, but the Academy provides in-depth insights tailored to specific application areas.

Are there already trends or technologies that you consider to be game changers for the industry?

Kammann: Sustainability and efficiency are driving major innovations. One of the key developments is the shift toward non-toxic, aqueous-based inks for non-porous substrates like plastics. While further advancements are needed to fully replace traditional UV-curable or solvent inks, this transition is crucial for improving recyclability and environmental impact.

Another significant trend is energy efficiency, particularly the move from traditional mercury UV curing to UV LED curing. This change not only reduces energy consumption but also enhances process sustainability, making it a key focus for the industry.

How important is K as a platform for introducing innovations such as inkjet technology to an international audience?

Kammann: K is the leading trade show for the plastics industry, making it an essential platform for showcasing advancements in decoration technologies like inkjet printing. While decoration is a smaller part of the exhibition, K provides a focused environment to present new products, techniques, and technological breakthroughs to a highly relevant audience.

Recent editions of the show have highlighted growing emphasis on sustainability, with key topics including recycling, eco-friendly products, energy efficiency, and carbon footprint reduction. These themes will continue to shape discussions at the upcoming event, reinforcing the role of inkjet technology in driving both innovation and sustainability in plastic decoration.