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Project Summary:
This project will introduce flexibility into ceramic decal manufacture by transferring and adapting digital printing used in carpet production for the final stage of production (covercoat application). Covercoat is a polymer layer applied to every printed decal to protect against damage when it is handled and applied to the product.

The correct covercoat shape is applied currently to the decal by screen printing. Ink Jet printing (IJP) techniques will be transferred and adapted. Results will be demonstrated and disseminated both after laboratory and factory tests. The project will also produce a protocol for the transmission of sheet layouts between designers and the organisation producing the covercoated decal via the internet.

Project Partners:
ATC
CERAM
DCS
Emery Colours
Imagees - Withdrawn
McPherson
Polycarta
Screeen Printing Association
Willett Limited

Need:
The majority of ceramic decals are produced by screenprinting. As the final production step, a polymer layer is applied to every printed decal to protect against damage when it is handled. As the production of the screens is relatively expensive and time consuming, digital printing techniques have the potential to transform the production process. At present, however, digital decoration techniques have yet to make a significant impact on manufacture of ceramic whitewares worldwide, yet alone in the UK sector. Significant technical barriers must be overcome before the technology will be adopted by the sector.

Solution:
Carpet printing has recently benefited from the development of a single ink jet valve printing technique. This technology is being transferred and adapted for decal covercoating. Feasibility studies are selecting covercoat media and paper suited to digital printing, and demonstrating the ink jet printing head. A prototype ink jet printer will demonstrate the effectiveness of the system, and finally a second prototype will be built for factory trials.

At the end of the project a digitally controlled covercoating system and a data transfer protocol for exchanging design data will be produced.

Benefits:
Specific benefits to the manufacture of decals will include:

• Quicker response times and lower costs
• Increased process flexibility
• Improved product quality
• Space and energy saving

The project should also stimulate wider application of digital printing in decal manufacture. Although not achievable in this project, the ultimate delivery of total use of IJP and UV curing for fast print drying will produce 12-colour decals in 2-3 days instead of the current timescale that could be up to 13 days. This means the time to deliver decals could be reduced by up to 75%.