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Quick-Start Guide

 

Choosing the right print-head colour configuration for industrial UV inkjet jobs


 

1 Identify the substrate

 

Substrate colour / translucency

Typical requirement

Recommended first filter

Clear, translucent, dark or coloured(window film, glass, black acrylic, brushed metal)

Lay an opaque white underlay before colour

Keep at least one dedicated white row(any code that starts with W… or contains _+_WW)

White or very light (paper, white vinyl, foamed PVC)

No white needed; pure colour is fastest and cheapest

Drop all white rows; pick codes without W


 

2 Set the productivity / quality target

 

What matters most?

Practical effect

Configuration style

Top speed / lowest cost

Reduce dpi and split work over more rows so each nozzle fires slower

Double-row colour (DA_CMYK-, DA_…, WW_CMYK)  Add a 2nd white pair (WWWW) if opacity must stay high

Fine detail or tiny text

Keep 600 × 1200 dpi or add light colours (Lc/Lm)

• Keep to single-row colour (CMYK-, CMYKLcLm-) • Use a single white row at the same dpi (WW_CMYK)

High-opacity in one hit

Two white banks fire in parallel

• Prefix WW or suffix _WW, _+_WWWW

Scratch/chemical resistance

Print and cure a clear varnish immediately

• Group 6 “white ▸ colour ▸ varnish” codes (e.g. TA_+_CMYKVVWW)

Special effects / primers

Run primer or varnish in its own row

• Group 8 “special modes” (TA_+_CMYKPPWW, TA_+_VVVVVV…)


 

3 Match the head-count you actually have

 

Installed head rows

Maximum practical configuration

1 row (compact)

Any single row code (CMYK-, CMYKLcLm-)

2 rows

Double-row codes: DA_… or WW_CMYK…

3 rows

Triple-row codes: TA_… sandwich modes

>3 rows

Mix & match: add varnish or dual white without slowing colour

Tip: Don’t load a configuration that expects more physical heads (heads field) than you have; the controller will down-rate speed or refuse the job.


 

4 Cross-check resolution vs. carriage speed

 

Channel

Safe firing limit (typical Kyocera / Ricoh industrial heads)

Colour (CMYK, Lc, Lm, OZ)

6–10 kHz → 70–90 m min at 600 × 600 dpi

White (TiO₂-loaded)

4–5 kHz → about half that speed unless you double nozzle count

Varnish / Primer

8–12 kHz (small drops) → rarely the bottleneck

If white is present, size its nozzle bank (single vs. double) so that white and colour rows share the same linear speed; otherwise the slowest one sets the ceiling.


 

5 Pick the configuration code

 

Follow the decision in steps 1-4 and choose from the file:

Common use case

Example code(s)

Fast banner run on white PVC

DA_CMYK- (double-row colour, no white)

Window cling on clear PET

WW_CMYK_WW or WW_CMYK (dedicated double white + colour)

High-opacity one-pass on black ACM

TA_+_CMYK_WWWW (triple-row, four whites on top)

Luxury label with tactile varnish

TA_+_CMYKLcLmVVVVVVWWWWCMYKLcLm (white–colour–varnish sandwich)

Budget corrugate, limited to one head row

CMYK-


 

Cheat-sheet of key parameters

 

  • Substrate colour / transparency → decides whether you must include white.

  • Required opacity → number of white nozzle banks (W, WW, WWWW).

  • Speed vs. resolution → rows per colour (single, double, triple) and dpi choice.

  • Special coatings → extra rows for varnish (V…) or primer (P…).

  • Installed hardware → physical head count must meet the configuration’s heads value.

  • Ink duty cycle / head life → the more rows you dedicate to a colour, the cooler the heads run.

 

How the white ink  can be deployed?

 

Below we slice your layouts only by what they do with white ( W ).

Think of the print zone as a conveyor: Row 1 fires first, Row 2 a few centimetres downstream, Row 3 last.

W1 W2 … = nozzle pairs in one physical row; the heads field tells you how many print-bar modules that row spans.

#

Arrangement

Example codes in your file

Physical idea

Typical use-case

Speed notes

A

White and colour in the same row

CMYKWW-, CMYKLcLmWW-, CMYKOZWW-, CMYKVW-

One 8-slot row carries both CMYK and 1 – 2 white pairs.

Entry-level machines; saves hardware slots.

Slowest: colour nozzles must wait for huge white duty-cycle.

B1

Single dedicated white row in front of colour

WW_CMYK, DA_+_CMYKWW-, DA_CMYK_+_WW-

Row 1 floods white, Row 2+3 lay colour.

Any transparent / dark media with normalopacity demand.

Carriage speed capped by one white row (usually ≈½ pure-colour speed).

B2

Same but double nozzle bank in that white row(W1 W2 W3 W4)

WW_CMYK_WWWW, DA_+_CMYKWWWW-, TA_+_CMYK_WWWW

Still one row, but twice the nozzles— they print even & odd pixels in parallel.

When customers insist on one-pass high-opacity yet want higher throughput.

+35 – 45 % faster than B1; still one row, so still the bottleneck.

C

Two distinct white rows (Row 1 and Row 2)

TA_+_CMYK_+_2x2W, TA_+_LcLmCMYK_+_2x2W

First two rows are all-white (even / odd split), third row colour.

Very opaque window graphics, day/night back-lits.

Each row runs at lower dpi (e.g. 600×600) → linear speed ~×1.7 over B1.

D

White in the middle – colour / white / colour “sandwich”

TA_+_CMYK_WW_CMYK, TA_+_CMYK_WWWW_CMYK, TA_+_CMYKLcLm_WW_CMYKLcLm

Row 1 colour, Row 2 white, Row 3 colour.

Industrial décor on clear film viewed from bothsides; protects white inside the stack.

Speed set by the singlewhite row (as in B1).

E

White as last row (over-print)

TA_+_CMYK_WWWW (colour, colour, white)

Adds a highlight or protective white key on top of colour.

Labels needing a scuff-resistant white spot, or metallic stock where white mask must sit on top.

Like D; still white-limited.

F

White, then colour, then varnish

Group 6 codes (e.g. TA_+_CMYKVVWW-, TA_+_CMYKLcLmVVVVVVWWWWCMYKLcLm)

Row 1 white, Row 2 colour, Row 3 varnish.

High-end packaging: opaque graphic plus immediate gloss/texture cure.

Same white limit; varnish fires fast so does not throttle line.

G

Colour-only (no white)

CMYK-, DA_CMYK-, TA_CMYK-, etc.

Nothing but colour rows.

Printing on white/opaque stock; fastest possible.

True double-/triple-row speed because no white bottleneck.


 

Why add more nozzles in the same row  vs. adding extra rows?

 

Option

What changes

Pros

Cons

Extra W heads in one row (W1 W2 → W1 W2 W3 W4)

Doubles active nozzles but keeps firing zone short.

• Retrofit without moving mechanics.• Better opacity or same opacity at ~1.4 × speed.

• Row still dictates carriage speed.• Pigment loading still stresses ink-delivery & mist extraction.

A second row of white

Adds another pass 50–100 mm downstream.

• Linear speed almost doubles (each row now prints 600 × 600 instead of 600 × 1200).• Lower drop frequency → cooler heads, longer life.

• Extra hardware slot & cost.• Longer print bar means larger footprint or slower media acceleration out of station.


 

Why put white first, middle, or last?

 

Position of white

Sublayer logic

Key benefits

Common pitfalls

First (under-print)

White hits substrate, colour lands on fresh white.

✓ Best colour vibrancy on dark/clear media.✓ Simplest RIP (single composite white mask).

• Longer cure: white has to pin before colour drops.• White limits speed.

Middle (sandwich)

Colour 1 ▼ • White ▼ • Colour 2

✓ Both sides of clear sheet show colour (back-lit).✓ White protected from scuff & yellowing.

• Adds a whole row yet still bottlenecked.• RIP must output three separations (C-W-C).

Last (over-print)

Colour ▼ • White

✓ White highlight/mask on metallic or textured stock.✓ Protects colour from abrasion.

• Over-print white must be perfectly registered; any stretch shows halo.• Some substrates don’t like heavy ink on top (cracking).


 

Quick decision tree for your operators

 

  1. Is the substrate non-white or transparent?

    • No → choose a colour-only preset (Group 1, 2, 7).

    • Yes → continue.

     

  2. Is one pass of white opaque enough?

    • Yes → choose a single dedicated white row (B1/B2).

    • No → promote to two white rows (C) or quadruple white in one row (B2) if hardware slots are full.

     

  3. Do you need a colour/white sandwich or over-print?

    • Yes → pick D (sandwich) or E (over-print).

    • No → stay with under-print (B1/B2/C).

     

  4. Do you need varnish in the same pass?

    • Yes → choose any Group 6 mode (F).

     

 

Use the table up top to match the final requirement to a code in your config file.