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
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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
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Is the substrate non-white or transparent?
-
No → choose a colour-only preset (Group 1, 2, 7).
-
Yes → continue.
-
-
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.
-
-
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).
-
-
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.