innovative solutions for rapid and cost-effective prototyping...

22 . Acimac handbooks - 2014 Edition

Innovative solutions for rapid and cost-effective prototyping

ity to support multiple ink changes or simply because of quality issues deriving from the fixed transversal printhead resolution. For real prototyping or small just-in-time production runs, certain activi-ties need to be performed quickly, re-liably and cost-effectively:• Scanning of stone, wood and other

natural materials• Automatic colour management

Glaze and colour producers, third fire ceramic tile producers and labo-ratories are experiencing a growing need to perform tile prototyping as part of their R&D activities and for small special production runs, such as those with precious metals. For these kinds of activities, normal single-pass digital decoration print-ers are often not sufficiently versa-tile, either due to their limited abil-

• Plotter with quick ink change.Intesa’s solution consists of three devices that can be combined per-fectly to meet the needs of ceramic glaze and colour laboratories, third fire tile producers and companies wishing to prototype products with-out occupying lines and single-pass digital machines.

by Alessandro Beltrami

IMAGO – XL IMAGE SCANNER

tion systems. It was created by adapting one of the best commercial optical sys-tems on the market, produced by Seiko Epson, and fully exploits the system’s ability to acquire details and colours on smooth and slightly textured materials. With an optical density of 3.8 DMax it can detect contrast on the most strongly variegated stone, while the native colour depth is 48bit. This means that it can acquire al-most 300 trillion (3x1014) colour combinations compared to the 16 million colours of normal 8 bit per channel devices!

Ceramic producers often require a spectral scanner, so let’s look at

Imago is a photographic scanner that acquires images of stone, wood and other flat materials with-out the need to break them into small pieces. Imago uses 2,400 dpi autofocus optics and is designed to reproduce colours and details with a high degree of accuracy so that they can be replicated with Intesa digital printers with the aid of the Crono colour management system.Its solid structure enables it to easily handle ceramic panels up to 1x1.5 metres in size and weighing up to 150 kg. The project was developed by Inte-sa with the goal of obtaining a ro-bust and simple machine that would be easy to install and above all much less expensive than other acquisi-

why Imago may offer a valid alter-native. A spectral scanner normally consists of a high-resolution camera but with a lower DPI than the native 2,400 of Imago. Filters are used to split up light sole-ly across the visible spectrum (spec-tral scanner) or including part of the infrared and ultraviolet component (hyperspectral scanner). This means that the same device can acquire graphics and testcharts, whereas with an RGB scanner like Imago a spectrophotometer is re-quired. The list of the pros and cons of Ima-go compared to a spectral scanner shows that it is difficult to make a direct comparison between the two devices:

FIG. 1 - Imago - XL image scanner FIG. 2 - Imago - XL image scanner

Acimac handbooks - 2014 Edition . 23

Spectral scanner Imago

Pros Colorimetric precision

• The price is a fraction of that of a spectral scanner.• Maximum versatility and ease of use by any graphics operator.• High acquisition speed (typically 15 min/m2 for 600 DPI high-quality

scanning).• Optics and lights produced for more than 15 years by Seiko Epson,

which has customer support centres all over the world.• Standard Epson software for PC and OSX.

Cons

• Very high price.• Light/shadow contrast not optimal.• Low acquisition speed.• Optics and lights produced in small quantities and difficult to find on

the market.• Need for custom software

A spectrophotometer is required to complete the workflow

the same results were achieved as with the use of a spectral scanner. The ability to reproduce a materi-al with precision, which is the key strength of a spectral scanner, be-comes pointless if the designer has

From our experience at Intesa, we believe that a spectral scanner is not necessary in the ceramic indus-try. In all projects carried through using Imago (more than 100 in var-ious factories), in the worst cases

to make colour variations or per-form graphic design processing. In this case, because Imago is a tra-ditional RGB scanner it can gener-ate a more versatile if theoretically less precise input file.

CRONO DESKTOP 3 + SPECTROPRO – CERAMIC COLOUR MANAGEMENT

FIG. 3 - Crono

ly suitable for companies looking to start up digital ceramic production as it offers them a quick and simple way of achieving a good level of colour quality while minimising the number of trials required before commencing production. Crono manages ceram-ic colour in xCLR mode, so it is in-

Crono is a system developed by INTESA. Imaging since 2009 for col-our management in the pre-printing stages of the digital decoration pro-cess. Crono software facilitates the use of digital images and of design and production data in the various processing stages. It is particular-

dependent of the CMYK model. This enables it to handle digital configu-rations with multiple colours (up to 8 or more), independently managing similar shades of colour on the ma-chine. When interfaced with Imago and Colorscan 1010 it creates the ideal workflow for glaze and colour producers and for ceramic R&D lab-oratories.

Version 3 of the Crono system intro-duces an array of new features, all of which have been developed inter-nally by the Intesa Imaging research centre. The main changes come from the new Crono Image Library™ which forms the basis of all new Intesa software: Crono Desktop, Crono Production, Crono Cap and the operational soft-ware of DHD and DHW digital ma-chines. Crono Image Library™ allows images to be processed with state-of-the-art technology, using the mul-tithread and video card resources to


speed up all operations.

Improvements:• Up to three times faster over a

complete workflow compared to the previous version.

• Video preview and other opera-tions optimised for processing Sacmi Continua® and Continua+® line files.

• New CMYK and Multicolor profiler with proprietary mathematics and algorithms, compatible with 0/45° spectrophotometers (e.g. X-Rite EyeOne and Barbieri LFP) and d/8° sphere spectrophotometers (e.g. X-Rite SP62/64 and Konica Minol-ta CM 2500/2600d).

• The reliability and size limitations of the plug-in for Adobe Photo-shop™ for Windows have been im-proved.

• Improved connection with Tecno-grafica database.

• Improved HotFolder function with

halftoning capacity for complete automation of workflows with col-our management and screening.

• Crono Image Library™ allocates computer resources intelligent-ly to conserve RAM and to make maximum use of processors. Var-ious strategies are used for small images or large sheets, including images larger than the comput-er’s physical RAM.

• Auto Update function with auto-matic download and installation on request.

New functions:• Advanced Ink Saving workflow

compatible with large profiles, with preview of results and infor-mation on savings.

• Complete management of PSD/PSB and TIFF files with up to 11 alpha channels.

• Generation of test runs with au-tomatic notes written on the tile.

• New Layout section with rota-tion, size change, cut and panel-ling functions; it is now possible to import a complete sheet and cut the sizes directly with Crono.

• Option with SpectroPro™ auto-mated spectrophotometer to create perfect profiles on tex-tured surfaces (e.g. Continua+®) and tiles with finishing glazes and grits.

• Advanced manual change with In-tesa Tone Compensation™ func-tion and other utility tools.

• Plug-in for Adobe Photoshop™ for Apple OSX.

• Halftoning capacity with various algorithms and drop division pa-rameters.

• Management of “effects” and “white” with levels sent separate-ly to different machines (e.g. DH-D+DHW project in a single file).

• Creation of master files for Crono Production 3.

FIG. 5 - Crono: image acquisition of marble and stone

FIG. 6 - Crono, profiling and separation FIG. 7 - Crono, advanced manual changes FIG. 8 - Crono, production preview

FIG. 4 - Crono: image acquisition of marble and stone


FIG. 9 - Spectro Pro

COLORSCAN 1010 – CERAMIC PLOTTER

high-definition images to be printed in four-colour or multicolour mode. Colorscan 1010 can be equipped with a maximum of 8 colour modules with the option of a further 8 mod-ules on stand-by for rapid ink chang-ing. This means that up to 16 colour bars are available to simulate all the cus-tomer’s ink combinations with a high degree of precision. The bars can be interchanged to perform sequence tests to be replicated on the sin-gle pass printer. Colorscan 1010 can operate in “single pass emula-

Colorscan 1010 is a compact and versatile plotter, ideal for research, development and prototyping activi-ties in the ceramic sector. The automation system consists of a Cartesian robot movement and en-sures high printing precision. The movements of the X axis (car-riage movement) and of the Y axis (table movement) are powered by lin-ear motors. The Z axis movement (carriage up/down) is managed by a stepper mo-tor.The graphics program allows

tion” mode to reproduce the typi-cal discharges of Xaar GS6 or GS12 printheads with multiple passes and achieve perfect, defect-free pro-totypes. For third fire production, Colorscan 1010 operates in “high discharge” mode, using multiple passes to deposit a greater quantity of colour than is possible in a normal single pass. These modes are man-aged using a special version of Crono Production, the software that func-tions as an RIP and adapts perfectly to the Crono Desktop graphic design firm workflow.

FIG. 10 and 11 - Colorscan 1010

The Spectro Pro spectrophotome-ter is recommended for use in ce-ramic laboratories and glaze and col-our factories. When a ceramic surface consists of glossy glazes, textures or finishes such as grits or protective glazes, it is very difficult for a normal 0°/45° spectrophotometer to read the col-our accurately and repeatably. Incor-rect measurements are detrimental to the generation of ICC profiles and impact on the entire Crono workflow, nullifying the benefits of soft proof-ing and adversely affecting image contrast. Spectro Pro is a Crono

option for automat-ing integrating sphere spectrophotometers, which are normally used in ceramic laboratories for formulating colour-ed glazes and for read-ing linearisations and testcharts in difficult measurement condi-tions. Crono Desktop can make use of read-ings made by sphere spectrophotometers in both SPIN mode and SPEX mode.


GLAZING AND DECORATION IN THE DIGITAL AGE

The DHD series can be fitted with all types of Xaar 1002 printheads, in-cluding the brand new GS40 heads unveiled at Tecnargilla 2014. DHD printers offer a number of ma-jor improvements and innovations over previous versions of Intesa ma-chines. In particular, the ink circula-tion and feeding systems have been entirely redesigned to ensure a very high level of performance. The electronics are also complete-ly new. All Intesa machines now use proprietary electronics developed in-ternally by the Sacmi Group, which ensure very high performance in terms of data transmission rates,

Intesa is continuing along its path of technological development with the goal of complete digitalisation of the ceramic glazing and decoration pro-cesses. For this purpose, it is unveiling a completely new range of digital print-ers marketed under the Sacmi brand name, demonstrating how its opera-tions are becoming increasingly inte-grated with those of its Imola-based parent company. For inkjet printing, Intesa is propos-ing its DHD series of decorating ma-chines based on technology from Xaar, the world leader in inkjet tech-nology.

manufacturing flexibility and reliabil-ity, while at the same time allowing for perfect integration between the various digital applications that are to be found today on a ceramic glaz-ing and decoration line.Furthermore, the DHD printer man-agement software has a simple and intuitive graphic interface that is easy to use by operators.The DHD digital printer range com-prises models DHD708 (maxi-mum printing width of 697 mm), DHD1108 (maximum width 1120 mm) and DHD1308 (maximum width 1390 mm). Alongside these models, which can be used to decorate all sizes up to 1200 mm after firing, Intesa is al-so proposing a digital printer version that has been specially designed for decorating very large format ceramic panels and for installation on Sacmi’s Continua+ production lines. With its maximum printing width of 1882 mm and the possibility of installing up to 8 colour bars, the DHD 1808 has technical, construction and function-al characteristics that are intended specifically for integration with the Continua+ production cycle. Equipped with an individual cleaning system for each colour bar, the DHD 1808 can be programmed to per-


NOTES

form bar washing cycles in the time between the passage of one tile and the next, without the need to halt production.

In view of the extraordinary benefits that digital technology offers for the decoration stage, the entire ceram-ic sector is striving to expand digital applications. In particular, special materials are being used to bring new aesthetic possibilities to the traditional deco-ration process, including increasing-ly rich natural textures, colours and effects. However, as these materi-als are still solvent-based and have a sub-micron particle size, they often have the drawback of high costs and limited application potential.To be able to produce tiles with the

real material look and feel that can-not be achieved using inks alone, Intesa has developed the new HW printing technology for controlled application of ceramic glazes. HW technology can apply wa-ter-based glazes with particle siz-es greater than 3 microns (range 3 - 12 micron). It is capable of depositing glazes in quantities of between 200 and 1000 grams per square metre for either full-field applications (engobes, textures) or specific spot applications inte-grated with traditional ink decora-tion.Initially designed and developed in the Sacmi Group’s research lab-oratories, HW is now brought to the ceramic industry by Xaar with the brand new Xaar 001 print-

head, featured on Intesa’s Glaze-jet and DHW series digital printers. The Glazejet 330 laboratory plot-ter, complete with a printing sta-tion and DropWatcher system, has already been adopted by numerous glaze and colour producers for their glaze research and development ac-tivities. The Glazejet 1000 plotter is suit-able for prototyping and developing large-size products. During Tecnargilla 2014, Intesa al-so unveiled the DHW 700 digital printer, the first single-pass digital machine for operation in a continu-ous industrial process. DHW can be synchronised with conventional ink-jet printers and allows a fully dig-italised glazing and decoration line to be created.

innovative solutions for rapid and cost-effective prototyping...

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