Choosing the software to drive your digital inkjet press

When developing your first or next digital press, the software you use to drive it will be a key factor in its success, both for the data rates and output quality you can achieve. The time it takes to get your press to market based on the engineering effort involved to deliver and integrate that software is also a consideration.

A simple user interface to get  you started

The Press Operator Controller (POC) is an example front end or user interface available with Harlequin Direct™ , the software solution that drives printhead electronics at ultra-high data rates while retaining high output quality. The POC provides you with an initial working system, so you’re up and running without any significant in-house software development. We provide you with the source code so that you have the option to update and integrate it as part of your production system.

I have created a short video to show you its main functions:

You can find out more information about the Direct™ range of products by visiting our website: https://www.globalgraphics.com/products/direct

Further reading about considerations when choosing your digital inkjet press:

  1. How do I choose the right PC specification for my digital press workflow
  2. Future-proofing your digital press to cope with rising data rates
  3. Looking to reduce errors with simple job management, keep control of color, and run at ultra-high speed for jobs with variable data?

About the author

Ian Bolton, Product Manager, Direct
Ian Bolton, Product Manager – Direct

Ian has over 15 years’ experience in industry as a software engineer focusing on high performance. With a passion for problem-solving, Ian’s role as product manager for the Direct range gives him the opportunity to work with printer OEMs and break down any new technology barriers that may be preventing them from reaching their digital printer’s full potential.

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How do I choose the right PC specification for my digital press workflow?

When planning the implementation of your first or next digital press, the PC specification you choose to run your software workflow will play an important part in the data rates you will be able to achieve. Assuming you are not bottlenecked by disk drive performance due to requiring intermediate disk accesses, you can generally expect data rates to rise with the computational power of your PC.

It might therefore make sense to review the PassMark scores for a range of CPUs within your budget and make your choice based on that, but this alone won’t be enough to tell you whether you’ll be able to drive your printer at full rated speed. Similarly, you may already have an existing PC system in mind but need to know if it will be powerful enough for your new requirements.

Ideally, you could set up an evaluation system to run some typical print jobs to get a definitive answer, but this could be costly and labor-intensive, especially if this is your first digital press.

It’s for this reason we created Direct Benchmark™: an analysis tool that exercises Harlequin Direct™, our ultra-high data rate RIPping and screening solution, with your choice of press configuration and print jobs, stepping through a tuning cycle to obtain a series of data rates and line speeds that can be achieved.

There are two main ways Direct Benchmark can help you: firstly, if you have an existing PC system to run on, you can install Direct Benchmark and gather your own results; secondly, you could base your decision on a database of Direct Benchmark results we are gathering here at Global Graphics Software from running a variety of jobs on a range of PC specifications.

Running Direct Benchmark yourself

Whilst a real Harlequin Direct system would be connected to printhead electronics and driving your press directly, the Harlequin Direct invoked by Direct Benchmark doesn’t require this connection. This makes it very quick and easy to install and start gathering performance numbers. The screenshot below shows the settings you can use to reflect your printer configuration and define the print jobs to benchmark.

During benchmarking, you will be presented with a screen showing statistics for each run and a real-time graph of data rate at the bottom, and then you will be able to export the results at the end. If you would like to see Direct Benchmark in action, you can view a short demo here:

Using the Direct Benchmark database

If you aren’t in a position to run Direct Benchmark yourself, we are in the process of gathering results for a range of press configurations and print jobs, running on a variety of PC hardware specifications. This is being conducted in conjunction with Proactive Technologies, who are providing access to some of the machines we’re using. Whilst it is too early to draw any conclusions or share our results at this stage, if you have some typical print jobs and a press configuration in mind, please get in touch with me, ian.bolton@globalgraphics.com, because we may be able to generate the results for you.

For more information about Direct, please visit globalgraphics.com/direct

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About the author:

Ian Bolton, Product Manager, Direct
Ian Bolton, Product Manager – Direct

Ian has over 15 years’ experience in industry as a software engineer focusing on high performance. With a passion for problem-solving, Ian’s role as product manager for the Direct range gives him the opportunity to work with printer OEMs and break down any new technology barriers that may be preventing them from reaching their digital printer’s full potential.

 

How to accurately calculate the ink costs for your digital press

There are many costs that can impact your profitability when running a production digital press, from power consumption to the substrate you’re printing on. One of the most variable costs is ink consumption, which often varies from job to job and therefore can be difficult to estimate. As you might expect, the content to be printed is the key determining factor, but you also need to consider the resolution, screening method, drop sizes and choice of colorants. This can bring quite a challenge for a press shop when quoting for a job, especially if the client is open to hearing a range of options.

Even with a static job that might be suitable for a test print run to get a cost that can be multiplied for the number of copies, it’s still not ideal to have to spend any time or other resources using the actual press. It’s much better to be able to get an accurate ink cost estimate away from the press, which is where our Job Cost Estimator comes in. It’s available as part of our Direct™ software range as well as our Harlequin Host Renderer™ and ScreenPro™ products. It uses the same setup that drives your printer, calculating a very accurate estimate of the ink cost for a specific job. Self-contained, it doesn’t require any connection to your printer, which makes it ideal when you want to give a job cost indication away from the print shop.

The screenshot shows a calculation performed using our Job Cost Estimator for a 1200x1200 dpi version of our two-page Direct brochure, screened with 4-drop pearl.

The screenshot above shows a calculation performed using our Job Cost Estimator for a 1200×1200 dpi version of our two-page Direct brochure, screened with 4-drop pearl. Under Cost Per Page, this is the average cost per page per colorant based on the two pages that were analyzed, with a final row showing the total (All). This is then multiplied by the total pages and the number of copies to get the Cost Per Job for each row.

Obviously, no costs can be determined without knowing how much the inks cost per liter, so you can set these within the application. Similarly, you will need to configure your printhead(s) to specify how many picoliters of ink are used per drop size.

As you can see from the left image above, we have assigned a different printhead for Black called Budget_PrintHead, which will have fewer picoliters per drop size than the Default_PrintHead shown on the right, to represent a possible response to a hypothetical jump in the price of black ink.

The Job Cost Estimator has been designed to be extensible, so it would be possible in future to incorporate other costs, such as paper, or factor in ink used periodically for nozzle refreshing, for example.

If you’d like to know more about the Job Cost Estimator, watch my short demonstration here:

For more information visit the Direct pages on our website: globalgraphics.com/direct

To be the first to receive our blog posts, news updates and product news why not subscribe to our monthly newsletter? Subscribe here

About the author:

Ian Bolton, Product Manager, Direct
Ian Bolton, Product Manager – Direct

Ian has over 15 years’ experience in industry as a software engineer focusing on high performance. With a passion for problem-solving, Ian’s role as product manager for the Direct range gives him the opportunity to work with printer OEMs and break down any new technology barriers that may be preventing them from reaching their digital printer’s full potential.

Future-proofing your digital press to cope with rising data rates

When we hear the phrase “big data”, we’re meant to think of extremely large data sets that are too complex to process in traditional ways. But, in the context of the next generation of digital presses, you’d be forgiven for thinking it refers to the ultra-high data rates required to drive them.

For example, consider a typical narrow-web label press: 13 inches (330mm) wide, 4 colors, 600x600dpi, running at 230 fpm (70m/min). This requires 0.9 GB/s of raster data to drive it at its rated speed.

Assuming next year’s press adds three more colors (Orange, Green and White) and is upgraded to 1200x1200dpi and expected to run a little faster at 330 fpm (100m/min), the required data rate will jump to 8.6 GB/s: almost a factor of ten increase!

Already this is a data rate far in excess of what the fastest solid-state drives can manage, so what hope is there for a traditional disk-based workflow when moving to 20 inches wide, duplex or 200m/min? Clearly, any part of the workflow involving a disk drive is going to become a bottleneck.

Ditch the disk with Direct
Ditch the disk. Rather than write intermediate raster files to disk between RIPping and screening, or between screening and the printhead electronics, everything takes place in memory.

This was one of the reasons behind the creation of Direct™, the integrated software pipeline we announced at the end of April. Rather than write intermediate raster files to disk between RIPping and screening, or between screening and the printhead electronics, everything takes place in memory.

There’s more to future-proofing your press than eliminating comparatively slow disk accesses, however. You’ll need a system that’s scalable and built from the fastest components, which is why Harlequin Direct™ is composed from a configurable number of Harlequin Host Renderer™ and ScreenPro™ instances working in parallel to make the best of the most powerful desktop PCs available.

When it comes to adding new colors or supporting duplex, the scalability extends to multiple Harlequin Directs across multiple PCs, one per print bar.

When it comes to adding new colors or supporting duplex, the scalability extends to multiple Harlequin Directs across multiple PCs, one per printbar.

An added advantage of this approach is that each printbar need not use the same resolution or drop-count etc. For example, you might wish to use a lower resolution and disable color management for white or varnish. Our Press Operator Controller user interface is supplied to manage your configuration, along with submitting and controlling your print jobs.

Our Press Operator Controller user interface is supplied to manage your configuration, along with submitting and controlling your print jobs.

The beauty of a software-only solution like Direct is that once you have built it into your workflow, you are free to upgrade your PCs over time for greater performance without any further software integration expense. A Direct-based system will evolve as your needs evolve, making it the ideal choice for future-proofing your next digital press.

For more information about Direct, please visit globalgraphics.com/direct.

To be the first to receive our blog posts, news updates and product news why not subscribe to our monthly newsletter? Subscribe here

Ian Bolton, Product Manager, Direct
Ian Bolton, Product Manager, Direct

About the author:
Ian has over 15 years’ experience in industry as a software engineer focusing on high performance. With a passion for problem-solving, Ian’s role as product manager for the Direct range gives him the opportunity to work with printer OEMs and break down any new technology barriers that may be preventing them from reaching their digital printer’s full potential.