When Continuous Inkjet is the Right Choice for High-Speed Lines

Mid-America Packaging’s Equipment Application Deep Dive – When Continuous Inkjet/High-Resolution is the Right Choice for High-Speed Lines

February 26, 2026

On high-speed packaging lines, printing variable data is not optional. Date codes, lot numbers, shift codes, barcodes, and serialization marks are essential for traceability, compliance, and customer requirements. When codes fail, the consequences are immediate: rework, QA holds, scrap, rejected shipments, and lost production time. In this deep dive, we’ll break down how continuous inkjet (CIJ) or high-resolution (high-res) works, what makes it uniquely suited for high-speed production, and when it is the best choice compared to other coding technologies.

What Continuous Inkjet/High-Res Actually Does on the Line

Continuous inkjet printers operate by generating a continuous stream of ink droplets. These droplets are electrically charged and deflected to form characters, numbers, or barcodes. Unused droplets are recirculated back into the system.

This non-contact method allows high-res systems to print:

On moving products
Across uneven or porous substrates
At high line speeds
With minimal sensitivity to small positioning variations

Because the droplets are extremely small and fired at high frequency, high-res systems can keep up with fast conveyor speeds while maintaining legibility.

For operations running 24/7, this reliability under real production conditions is what makes high-res a preferred solution.

Why High-Speed Lines Create Coding Challenges

As packaging speeds increase, the coding window shrinks.

At 200+ feet per minute, there is only a fraction of a second for the printer to place the correct code in the correct location. At these speeds, common issues begin to appear:

Product vibration
Slight case skew
Variable spacing
Substrate inconsistencies
Environmental humidity changes
Limited dry time

Technologies that require close proximity, slower cycle timing, or perfect product presentation often struggle in these conditions.

CIJ/high-res was designed specifically to tolerate variation.

When Continuous Inkjet Is the Best Choice

Continuous inkjet is typically the right fit when your line conditions include:

1) High Conveyor Speeds

If your line runs fast and cannot slow down for coding, CIJ/high-res provides:

- High character frequency
- Reliable droplet placement at speed
- Stable performance at extended run times

High-res systems are commonly used on beverage, food, corrugate, and consumer goods lines where uptime and throughput are critical.

2) Substrate Variability

CIJ/high-res performs well on:

- Corrugated cases
- Coated cartons
- Flexible films
- Shrink wrap
- Plastic containers
- Metal surfaces

Ink formulations can be matched to porous or non-porous materials, helping maintain adhesion even when substrates change between SKUs.

3) Uneven Product Positioning

Because CIJ is non-contact and can operate at greater throw distances than many other systems, it tolerates:

- Slight product height changes
- Minor case warp
- Inconsistent carton presentation

This flexibility reduces nuisance adjustments and helps maintain packaging line stability.

4) Long Production Runs

High-res systems are engineered for continuous duty cycles. With proper maintenance and fluid management, they support:

- Multi-shift operations
- Minimal downtime between batches
- Automated cleaning cycles

On high-volume lines, reliability matters more than maximum print resolution.

CIJ/High-Res vs. Other Inkjet Technologies on High-Speed Lines

While high-resolution drop-on-demand (DOD) inkjet systems excel at large-character printing and high-contrast case coding, they are often better suited for moderate-speed applications or when very bold graphics are required.

High-resolution printing typically outperforms in scenarios where:

Speed is the priority
Print size is smaller (date/lot coding)
Product presentation varies
Uptime consistency outweighs ultra-high resolution

Matching the coding technology to the real operating environment is critical. In many facilities, coding issues are not printer failures; they are application mismatches.

Real-World CIJ/High-Res Applications Supported by MAP

Mid-America Packaging supports continuous inkjet systems from:

Hitachi Industrial Equipment Systems
Squid Ink

Hitachi CIJ/high-res systems are widely recognized for fluid stability, precise droplet control, and long-term reliability in demanding production environments.

Squid Ink CIJ/high-res solutions provide versatile integration options and durable performance across secondary packaging applications.

MAP works with production teams to evaluate:

Line speed targets
Substrate types
Mounting location and stability
Environmental factors
Operator workflow
Future throughput goals

The goal is not simply to install a printer, but to ensure it performs consistently under real-world conditions.

Operator Considerations for High-Speed CIJ Success

Even the right technology requires proper setup.

On high-speed lines, teams should verify:

Printhead distance matches manufacturer recommendations
Mounting brackets are rigid and vibration-resistant
Ink type matches substrate
Preventative maintenance intervals are followed
Startup and shutdown procedures are consistent

Small mechanical drift can cause print distortion at high speeds. Stability in mounting and alignment directly impacts code clarity.

The Bigger Picture: Throughput, Compliance, and Waste Reduction

When CIJ/high-res is correctly matched to the application:

Rework decreases
Barcode scan rates improve
QA holds decline
Line speed remains stable
OEE improves

Coding should never be the bottleneck.

In many high-speed operations, continuous inkjet is not just a printer—it is a throughput protection tool.

Is Continuous Inkjet Right for Your Line?

Continuous inkjet is typically the best choice when:

You run high-speed conveyors
You print date/lot codes or small barcodes
Substrates vary across SKUs
Uptime and reliability are critical
You need non-contact coding with flexibility

If your team is slowing down the line to protect print quality—or constantly adjusting settings to keep codes readable—it may be time to evaluate whether CIJ/high-res is the better fit.

Mid-America Packaging works directly with operations, maintenance, and purchasing teams to match coding equipment to real production demands.

If you’re evaluating coding upgrades or troubleshooting performance on a high-speed line, our team can help you determine whether continuous inkjet is the right solution for your application.

Is Continuous Inkjet Right for Your Line? Contact your MAP representative today!

To speak with someone immediately, call: (314) 652-4583

For more information or questions, email us at: info@map-pack.com

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