About Hymmen - esma

Industrial Single Pass
Printing for Decorative
Melamine Surfaces
Printed Interior Decoration Conference 2014
About Hymmen
History
§  Founded in 1892
§  Family-owned company
§  Successful expansion of the company in the 70s
and 80s by industrialising of the isobaric Double
Belt Press
Theodor Hymmen
§  Since 2002 management by the 4th generation
with strong commitment to new technologies for
„continuous production systems“: Digital Printing
Dr. René Pankoke
About Hymmen
Development
§  Production sites in:
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Bielefeld-City
Bielefeld-Brackwede
Rödinghausen
Herford
Hamm
§  Employees in total: around 350
§  41 apprentices in 2014
Headquarter 1905 and 2011
About Hymmen
Product program
§  DBP
- Double Belt Presses
§  HCP
- Cycle Presses
§  KSA
- Laminating Lines
§  FBS
- Liquid Coating & Direct Printing Lines
§  DGP
- Industrial Digital Printing Lines
§  HTC
- Software & Automation
About Hymmen
DBP – Double Belt Presses
About Hymmen
DBP – Double Belt Presses
About Hymmen
HCP – Cycle Presses
About Hymmen
HCP – Cycle Presses
About Hymmen
KSA – Laminating Lines
About Hymmen
KSA – Laminating Lines
About Hymmen
FBS – Liquid Coating and Direct Printing Lines
About Hymmen
FBS – Liquid Coating and Direct Printing Lines
About Hymmen
DGP – Industrial Digital Printing Lines
About Hymmen
DGP – Industrial Digital Printing Lines
Hymmen Digital Printing Lines
Application fields
Laminates HPL/CPL
Laminate flooring
Laminate flooring
Doors and frames
Edge banding (ABS, PVC)
Garage doors
Skirting profiles
Furniture
Transition strips
Decor paper & finish foil
Facade boards
Hymmen Digital Printing Lines
Status quo
§  30 Hymmen digital printing lines
§  Overall installed capacity
status 2013 around 200 Mio. sqm
§  Department with over 40 employees
§  Inhouse R&D team for ink
development
§  Key customers invested in
follow-up lines
Industrial Digital Printing
„Industrial Inkjet“
Industrial digital printing
Individual.
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Fast.
Brilliant.
Industrial production quantities in spite of small batch sizes
Nearly no setup times
Minor capital commitment
Decor archive – fast reproducibility
Quick delivery resp. reaction times
Endless design variety
Customized product range
Industrial digital printing
Solution: Industrial „single pass“ digital printing
§  Industrial digital printing for
individual large scale production
§  Print heads fixed over the whole working
width (x-axis)
§  Continuous transport and printing
(y-axis)
§  Width up to 2.200 mm
§  Speed up to 50 - 75 m/min.
§  Ø capacity (up to 6.000 sqm/h)
≙ approx.1 soccer field
x
y
Industrial digital printing
Machine type JPT-W
§  Material
Web material
§  Models
280, 560, 840, 1400, 2200
§  Printheads
16 - 320
§  Effective working width 136 – 2.176 mm
§  Production capacity
up to 6.000 sqm/h
Industrial digital printing
Machine type JPT-C
§  Material
Board material
§  Models
840, 1400, 1700, 2200
§  Printheads
16 - 320
§  Effective working width 136 – 2.176 mm
§  Production capacity
up to 5.000 sqm/h
Industrial digital printing
Type JPT-W 1400 for decor paper
Industrial digital printing
Ink systems (UV- vs. Water-based)
UV-based ink
Standard ink (Europa)
Water-based ink
Hybride ink (Callisto)
•  Standard UV ink for numerous
applications
•  Special modified ink
•  Problems especially in single
pass
•  Full curing with UV light
•  1. reaction with UV light
•  Drying effects Ü Nozzle blocks
Ü Picture defects Ü Rejects
- LED or conventional lamp
•  Melamine impregnation
possible
•  Long cleaning cycles
•  2. reaction at pressing
•  Printhead lifetime
•  Paper growth
Industrial digital printing
Self recovery function
PZT
Nozzle
Source: Xaar
Industrial digital printing
Grey scale technology
Source: Xaar
Decorative surfaces industry
Decorative surfaces industry
Estimation of market size (w/o China)
Paper finished panel surfaces* (in total 7.100 Mio. sqm)
PRIP
14%
IMPR.
FILMS
19% EDGE
BAND
1%
approx. 50% printed
HPL/CPL
13%
LPL/DPL
53%
* Source: Munksjö Paper
Decorative surfaces industry
Market development – necessity of industrial digital printing
§  Strong trend towards individualization
§  Growing number of small batch sizes (< 1.000 sqm)
§  Situation of customers of decor paper industry
§  High storage costs due to minimum purchase quantities
§  High waste costs due to unconsumed paper material
§  Long delivery times, especially for individual decors
§  Fast reaction time to dynamic market changes required
§  Necessity of flexible production technology on industrial level
„Customized mass production“
Decorative surfaces industry
Production chain of decorative surfaces
Decor paper
producer
Board producer
Printer
- Laminating
- Pressing
- Sales of boards
Producer of
- Furniture
- Cabinets
- Flooring
- etc.
Decorative surfaces industry
Production chain of decorative surfaces
Board producer
Decor paper
producer
Printer
- Printing
- Impregnation
- Pressing
- Sales of boards
Producer of
- Furniture
- Cabinets
- Flooring
- etc.
Decorative surfaces industry
Most common product buildups (Melamine)
Melamine overlay
Melamine-faced boards
Decor paper
Wood fibre core layer
Melamine underlay
Backing
Melamine overlay
Laminates (HPL, Compact)
Decor paper
Phenolic resin paper
Phenolic resin paper
Backing
Decorative surfaces industry
Most common product buildups (UV coat)
UV Coating
Coated boards
Decor paper/Direct print
Wood fibre core layer
UV Coating (Backing)
Flat laminated boards
Decor finish foil
Wood fibre core layer
Decor finish foil
Melamine Process Technology
Product buildup „Callisto 06“ - melamine pressing
Dry pressing
Wet pressing
ü
ü
Melamine overlay
Printed paper (without opacity)
Melamine overlay (optional)
Opaque underlay (impregnated)
Printed paper (opaque, impregnated)
Core
Core
Melamine Process Technology
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Decorative purpose of the ink
Functional purpose of the ink
Process-related suitability of the ink
Substrate-related suitability of the ink
ð  Knowledge about downstream
processes
ð  Capability to support R&D processes
ð  Network with players within the
supply chain of decorative industries
Melamine Process Technology
Ink systems are critical for decor applications:
§  UV-based hybrid-ink for melamine-pressing „Callisto 06“
§  Ink modifications based on „Europa 05“ for special applications
(pigmentation, mechanical properties)
§  Adaption of ink / supply-system for transparent topcoat for special
surface properties
§  Dedicated R&D-team for ink- and substrate development
Technical Outlook
Outlook
Vision: the digital production line by
§  Today just decoration
§  Tomorrow could include all processes from primer to protection
including functional elements
Control Centre
Primer
Xaar 001
Decoration
Xaar 1002 GS6
Functional
Structure
Protection
Xaar 1002 GS6 Xaar 1002 GS40/SBX Xaar 001
Example for Customised Process
§  Customised plant for sectionalgarage door elements
§  Vertical digital print
§  CMYK CMYK decor print
§  Topcoat printing
§  UV-curing with surface effect
Plasma
Decor print
Topcoat print
70 m
Airjet drying
UV curing
Digital Decor Printing: Summary
ð  Fast digital printing at high resolution is
not the problem
ð  Customer value is created by embedding
of digital printing in decor process
environment
Thank you for your attention
§  Michael Hesse
Hymmen Industrieanlagen GmbH
Head of Division Plastics & Composites / Digital Printing
phone
+49 521 5806 142
email
[email protected]
More information under www.hymmen.com

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