Will inkjet redefine the future of book printing? — The Noel D’Cunha Sunday Column

Print-on-demand (POD) made its entry into India in the late 1990s, with some sources pointing to its beginnings around 1999, particularly with the introduction of Xerox’s Safida. However, it wasn’t until a decade later that POD became a common practice in the industry.

An industry expert, who has collaborated with two major digital press manufacturers, states that the POD sector truly started gaining traction in 2003, with a significant turning point occurring in 2018. He notes, “I don’t think 2010 or 2012 were pivotal years. Things really began to align when the Indian government banned the import of refurbished machines in 2017, which led to a surge in the jobber market.”

Recently, digital printing technology has become a favoured option for short-run projects and variable data printing.

According to data from PrintWeek, the number of digital presses is projected to reach 2,300 by 2023, with estimated equipment revenue hitting around Rs 450 crore, the highest recorded to date. Additionally, 2024 is expected to bring further growth.

This revival can be attributed to four key factors: an increase in the number of machines, higher print volumes per machine, the occurrence of the drupa event where new technologies and products are introduced, and a greater emphasis on binding.

Inkjet printing trends
The landscape of inkjet printing is rapidly changing. With manufacturers increasingly focusing on developing advanced inkjet technologies, 2024 marks a significant turning point, emphasising the broad acceptance of inkjet presses in various applications, most recently in book printing.

This evolution began with the introduction of Kodak CIJ heads over two decades ago. In between there was Kodak Prosper at Repro, who followed it up with an HP PageWide T240 web press recently. However, current trends suggest a shift in demand for less expensive inkjet presses rather than just technological advancements.

PrintWeek spoke to most of the inkjet press suppliers, who reckon that there are ten Atexco presses in the book printing segment, Miyakoshi has one (one in transactional printing), Founder, represented by TechNova has one unit installed, while Monotech has seven. Repro had three, including one HP PageWide and Kodak Prosper, and Manipal has one. That’s a total of 23 inkjet press installations in the book segment.

The latest to enter the fray is Nippon Color, which has entered into a partnership with Chinese manufacturer Oyang, a significant player in the global market for rotogravure presses, paper bag-making machines, non-woven bag-making machines, and inkjet digital printing. The partnership aims to utilise the potential of the expanding digital print market. Nippon Color will support Oyang's foray into India and ensure access to inkjet printing solutions.

Akshat Pardiwala, director at Nippon Color, says, "There is a significant shift toward print-on-demand (POD) services powered by digital printing in the book publishing sector. POD allows publishers to print smaller quantities and customise content while reducing the risk of overproduction. This approach also shortens production timelines and improves time-to-market for new titles."

In addition to the publishing sector, the demand for educational materials, niche publications, and short-run books is increasing in India. Pardiwala notes, "Digital printing is growing, offering opportunities for publishers to provide services and reduce inventory risks."

Service models for inkjet presses
The service model associated with inkjet printing has evolved significantly, offering more than just basic warranty and maintenance packages.

Ajay Aggarwal emphasises the importance of a robust service model, which he argues should be centred on customer success. “A superior service model involves active engagement and guidance for clients, helping them navigate their challenges and achieve their goals throughout their operational journey. This proactive approach can distinguish a manufacturer from its competitors.”

The differing demands of various equipment users also impact the service model. Pardiwala suggests adopting an annual warranty service aligned with actual equipment usage, likening it to an insurance model. By offering tailored follow-up services based on specific maintenance needs, suppliers can create a protective framework for both themselves and their customers.

Gurjit Dingra, assistant director - marketing and sales at Canon proposes an innovative hybrid model combining ink sales, a click-based pricing mechanism, and a maintenance and management contract (MMC). “This comprehensive approach ensures total coverage of the machine over its operational lifecycle while providing an accurate estimate of printing costs. Such transparency is invaluable for clients looking to manage expenses effectively,” he says.

On the other hand, Amit Khurana, CEO of TechNova at TechNova, advocates for flexibility, providing clients with choices between a per-page click model and a comprehensive AMC. “This customer-centric methodology is designed to optimise uptime and align with individual production needs, reinforcing the idea that one size does not fit all in service models.”

However, Ajay Raorane highlights challenges unique to the Indian market. Many buyers often prioritise minimising initial equipment costs, neglecting the significance of robust after-sales support. “At Domino India, bespoke service contracts are crafted to meet these unique requirements, stressing the importance of adherence to operational best practices to avert potential issues that could arise from non-compliance,”  Raorane says.

Choosing the right RIP for inkjet press engines
An effective raster image processor (RIP) is critical for maximising the output of an inkjet press engine. For firms looking to invest in inkjet technology, selecting a RIP capable of handling different book impositions has become a baseline requirement. While virtually any RIP/controller can drive an inkjet press, the right system drivers and components are essential for integration into a client's unique workflow.

Both Aggarwal and Pardiwala underline the significance of speed, good colour reproduction, and the ability to perform simultaneous RIP and printing.

Dingra of Canon raises a crucial point about the often-overlooked role of RIP/controllers in inkjet systems. “While many machines boast high-speed capabilities, they require equally strong controllers to process data rapidly, particularly in complex colour jobs and transactional printing environments,” he notes. Dingra. He also observes that many manufacturers, especially from China, neglect this vital aspect.

Pardiwala, however, mentions that Oyang’s self-developed RIP software leverages Global Graphics' Harlequin Kernel, enabling concurrent printing and RIP without compromising print speed, a critical factor in modern printing processes.

Khurana adds to the conversation by emphasising the necessity of digital front ends (DFEs) for effective inkjet printing. “DFEs manage direct-to-substrate processing, ensure colour consistency, and facilitate real-time quality control.” As a leading RIP provider, he says, Founder, offers robust inkjet workflow solutions designed for ultra-short-run book printing, featuring industry-leading RIP speeds and advanced job management capabilities.

Lastly, Ajay Raorane notes that the optimal solution varies based on the specific machine and its configuration. He explains that Domino provides a range of advanced controllers and RIPs tailored to different printing needs, including versatile offline RIPs for the K600i inkjet printers and various inline RIP options for the K630i monochrome book printing solution. He underscores that for monochrome devices, especially those printing variable data like QR codes, processing speed is critical to maximising output, while achieving optimal grayscale levels is essential for maintaining high-quality results in book printing.

Substrate flexibility in inkjet printing
At Drupa, a significant conversation emerged among industry leaders regarding the evolution of water-based inks and their potential applications across various substrates.

One of the significant advantages of inkjet technology is its compatibility with various substrates. Ajay Aggarwal emphasises, “The major advantage is that all offset papers—from 40 gsm to 200 gsm, coated or uncoated, including newsprint—can now be printed without a primer.” This change significantly lowers production costs, making digital presses more attractive to printers.

“Fundamentally inkjet was meant for uncoated stock. Because of the surface sealing ink wasn’t drying on coated papers. Now for coated paper you have to ink formulation called – Colour Grip, a solution on the areas marked to be compatible for coated stock,” says Dingra of Canon.

Furthermore, water-based inks are gaining traction as they are less harmful to the environment. “It eco-friendly benefits, a wide colour gamut and competitive per-page costs,” says Khurana of TechNova, which represents Founder in India. “Founder’s water-based inks are engineered to perform seamlessly on both coated and uncoated papers without the need for primers, enhancing their versatility and appeal in publishing.”

TP Jain emphasised the progress being made in aqueous ink formulations, revealing that a broader range of substrates is now being explored. Traditionally, water-based inks have been confined to porous and coated inkjet substrates. However, recent innovations are paving the way for their use on uncoated materials and unsupported films, particularly in the realm of flexible packaging. While these advancements show promise, Jain noted that it may still take time before these applications reach full commercial viability, with many new inks currently in development or beta testing phases at various original equipment manufacturer (OEM) sites.

Meanwhile, Akshat Pardiwala focused on the current applications of these inks, stating that they are primarily suited for offset paper. “The technology for coated papers is still undergoing testing, with further developments expected to be showcased at China Print 2025 next May.” This indicates a proactive approach within the industry to refine the capabilities of water-based inks.

To go third-party inks or not?
Businesses often find themselves grappling with the choice between original equipment manufacturer (OEM) inks and third-party alternatives. While cost considerations can tempt operators to explore these alternatives, a recent round of insights from leading figures in the industry highlights significant concerns regarding performance, compatibility, and the potential risks involved.

Ajay Raorane, representing Domino, emphasised the importance of using inks designed specifically for their machines. With a substantial investment of Pound 6.6-million aimed at enhancing their Liverpool facility, Domino is committed to developing inks that not only optimise performance but are also tailored to their equipment’s specifications. This bespoke approach is echoed across the industry, where the formulation of ink plays a crucial role in the overall efficiency of printing operations.

Contrastingly, Ajay Aggarwal raised a critical note regarding the risks associated with third-party inks. He asserted that inkjet press suppliers typically advise against using anything outside of original inks, highlighting the inherent dangers of ink incompatibility. “The printheads are the heart of an inkjet press,” he explains. "Using third-party inks can lead to damage, resulting in significant losses.” This caution is echoed by Akshat Pardiwala, who points out that their proprietary inks are finely tuned for optimal performance, significantly reducing the risk of damage to vital components.

Dingra of Canon adds to the concerns by stressing that inkjet systems require inks that have been rigorously tested and certified for compatibility. “The risk of failure when using untested third-party inks could far outweigh potential savings, making the gamble ill-advised for many operators.”

Despite the overarching caution, some industry leaders see potential in select third-party options, particularly Toyo. Khurana noted that while most inkjet OEMs restrict presses to specified inks, Toyo has established itself as a leader in the digital inkjet segment. He also hinted at a glimmer of hope for the future, suggesting that as the inkjet market expands, increased economies of scale might pave the way for more accessible and potentially cost-effective inks.

However, concerns remain steadfast. TP Jain reiterated Monotech's position, which discouraged the use of third-party inks. Instead, Monotech focuses on providing specially formulated inks that have been approved by printhead suppliers, ensuring high performance and reliability.

The dilemma of investment in book printing – monochrome versus colour

A significant question looms over many businesses—should a book printing firm invest in a basic monochrome model and later upgrade to a four-colour system? This inquiry is layered with complexity, as highlighted by industry experts who recently weighed in on the topic.

Raorane of Domino articulates a cautionary stance, emphasising the importance of aligning investment decisions with the immediate needs of the business. He observes that many customers often buy features they do not use, driven by the allure of obtaining the "best" option available, rather than focusing on current operational requirements. Raorane advocates for a methodical approach, suggesting that firms should choose machinery based on its ability to deliver optimal performance and a clear return on investment (ROI). “It’s far more effective to select a solution that maximises returns for the business you have today, rather than speculating on potential opportunities five to seven years down the line,” he explains.

Our discussions further reveals that while colour printing is gaining traction in India, a substantial volume of monochrome work continues to thrive. “Many businesses find success within this space, leaving open the option for upgrading or trading equipment when there is a solid business case” says Raorane.

Aggarwal of Insight offers a strategic perspective, suggesting that firms should first calculate the number of pages that can be printed cost-effectively on a digital press. Once this metric is established, firms can assess the viability of a potential investment. “If the ROI is positive, the decision becomes justifiable,” he asserts, adding that the level of risk appetite also plays a crucial role in the decision-making process. Aggarwal points out that new inkjet book printing presses present an immediate opportunity for high-margin profits, especially before competition drives margins lower.

However, the transition from monochrome to colour printing is not without its challenges. Pardiwala of Nippon highlights the complexities involved in upgrading, particularly due to differences in printhead technology and installation methods. “The current monochrome presses employing a one-head, two-colour overlay technology can achieve quality comparable to offset printing.” He generally advises against a straightforward shift from black to four-colour printing but does mention that transitioning to a dual-colour printing mode is feasible.

Dingra of Canon echoes the sentiment that the decision should hinge on job requirements. “If the bulk of production is monochrome, take a cautious approach. Learn the intricacies of inkjet digital printing before contemplating an upgrade,” he says. Some vendors, such as Canon, now offer machines that can be field-upgraded from a one/one configuration to full colour, providing flexibility for print firms navigating this decision.

Meanwhile, Khurana offers insight into the financial efficiency of monochrome presses, which provide excellent capital and operational expenditure efficiencies and typically yield quicker ROI. He acknowledges that “while colour models are increasingly popular for short-run jobs, sheetfed inkjet presses are particularly well-suited for varied job profiles despite their current lag in cost-effectiveness compared to monochrome counterparts”. Nevertheless, Khurana is optimistic about decreasing ink costs, which he believes will soon enhance the business case for colour printing.

Jain of Monochrom reiterates the importance of aligning investment decisions with the nature of the jobs a printing firm intends to pursue. “Monochrome jobs typically outnumber colour jobs; however, specific segments, such as children's or medical books, necessitate colour printing. Therefore, firms must carefully evaluate their needs before deciding whether to start with a monochrome or colour press.”

Finishing options
A well-rounded printing solution isn’t just about the press; it encompasses the entire finishing process as well. Print firms need to consider their finishing options to remain competitive.  Aggarwal highlights, “A press installed by a printer should support all binding options and accommodate a wide range of book sizes.”

Inline finishing systems—such as sheeting, folding, and binding—allow for seamless production and greater efficiency, enabling publishers to adapt quickly to market needs. With the potential for variable cutoff options, printers can handle distinct sizes for perfect binding, booklet making, and section sewing. Aggarwal notes, “This adaptability enhances production capability, making it easier for print firms to meet diverse client requirements.”

Pardiwala would rather take a practical perspective, suggesting that the choice of finishing options should be closely tied to customer order volumes and existing production methods. “For smaller orders—specifically those under 1,000 books.” He advocates for highly digitised small binding equipment, such as saddle stitching and perfect binding, to enhance efficiency. Conversely, he recommends that publishers with larger orders utilise high-paper printing methods, connecting these with folding and binding lines or adopting roll-to-roll printing combined with digital post-processing lines.

From a technological standpoint, Dingra points out that the cut-and-stick method, particularly from providers like Tecnau or Hunkeler, is the most popular finishing option within continuous feed inkjet production. This technique, paired with perfect binding, meets the demands of a rapidly changing market.

Khurana further expands highlighting TechNova-Founder's advances in printing technology. He says, “Our Tecnau-certified sheeting operates at speeds up to 120 meters per minute, perfectly suited for short-run, perfect-bound jobs that make up a significant portion of the market.” He insists that integrated folding devices are the optimal choice for specialised saddle-stitch operations, while standalone book block makers from brands like Tecnau and Muller Martini enhance high-speed production capabilities.

Jain introduces an innovative approach with the rollout of their unique press configurations. “While most suppliers offer either roll-to-roll or roll-to-sheet options, our offering advances the standard by providing a roll-to-folding option,” he explains. This new capability reflects the ongoing push within the industry to find more efficient, integrated solutions that can respond to diverse publishing needs.

A shift towards size flexibility
Traditionally, the industry has relied on standard models such as the 13-inch, 17.5-inch, and 20-inch presses. However, our discussions with industry specialists reveals a growing trend towards customised solutions, catering specifically to diverse customer needs.

Ajay Raorane from Domino notes that print width options have significantly expanded. The K600i inkjet printer offers widths from 108 mm to 782 mm. For book printing, the standard widths are 445 mm and 558 mm, while the X630i 4-colour corrugation press boasts a width of 1600 mm, highlighting the industry's adaptability.

Pardiwala of Nippon observes the market shift away from 13-inch presses towards 17.5-inch models, with the largest width reaching 26 inches (660 mm). Dingra of Canon mentions that while not all vendors offer adjustable widths, many have standard factory settings.

Khurana of TechNova emphasises the need to choose the right press based on job type. The 17-inch format is favoured for perfect-bound setups, while the versatile 22-inch format accommodates various applications, a trend seen in major brands like HP.

Jain of Monotech notes that while A3 duplex presses are standard, the demand has pushed towards the 26-inch (660 mm) format, highlighting the feasibility of customisation in size to meet client needs.

Future outlook for Indian book printing firms
As inkjet technology continues to advance, CEOs and decision-makers within Indian book printing firms need to remain vigilant. Aggarwal of Insight, asserts, “2024 has demonstrated that the future of book printing lies in inkjet technology. Going forward, web offset will be favoured for very high-volume book production, while digital web will cater to short- to medium-run demands.”

As the Indian book printing industry looks ahead to 2024 and 2025, industry experts are emphasising the need for CEOs to adapt swiftly to an evolving market landscape shaped by e-commerce and technological advancement. A key focus for these leaders should be the integration of new printing technologies, particularly in the wake of increasing consumer demands for just-in-time inventory.

Jain unequivocally states that “Book on Demand” capabilities are no longer an option but a necessity. He advocates for the adoption of digital inkjet presses, which not only cater to the immediate needs of the market but also ensure a more efficient production process tailored to the specific finishing and converting workflows. With a multitude of successful implementations proving the concept's viability, Jain urges CEOs to embrace this change to stay competitive.

Moreover, Pardiwala of Nippon highlights a critical area for growth: the development of small-batch business orders. He points out the vast potential for inkjet printing across various specialised segments, indicating a shift towards greater diversity in printing offerings.

Khurana brings a broader perspective to the discussion by noting the expansive opportunities within India’s flourishing e-commerce sector. “With the implementation of the National Education Policy (NEP), there is a surge in demand for short-run and on-demand book printing, aligning perfectly with the adaptability of digital inkjet. The rising popularity of trade books, educational materials tailored for test prep, and specialised content further propels the market.” He  also stresses that CEOs must seek reliable and high-performance printing solutions as India's role in global publishing expands—particularly amidst the China+1 strategy. Increased competition in the inkjet press market necessitates careful vendor selection, prioritising those with proven expertise and robust service frameworks. The forthcoming launch of TechNova’s sheet-fed inkjet system is poised to offer significant capital and operational cost efficiencies, providing a vital tool for export-focused production.