How CIJ Technology Solves Manufacturing’s Skilled Labour Gap

In industrial manufacturing, coding machines like printers must be set up, cleaned periodically, troubleshot when malfunctioning, and maintained with replacement parts. Traditionally, companies depend on skilled technicians, and engineers to keep their product identification equipment running smoothly, this includes continuous inkjet printers.

However, with the increasing labour shortage in recent years, production and manufacturing lines must keep their human resources focused on critical areas to maintain production uptime. Due to the demands of maintaining industrial printing systems, the maintenance staff is losing valuable time that could be spent on other critical machinery and being pulled away from areas that may need attention or improvement.

To start the MK-G Series, simply press the Smart Startup button. The printer will obtain the device status and automatically select the necessary cleaning method. Cleaning is performed only when required and uses minimal solvent each time, significantly reducing running costs.

It’s been a challenge to find and retain skilled staff who can set up and maintain traditional CIJs, leading to days of production delays. Advances in CIJ technology mean fewer professionals familiar with traditional coding systems.

With many manufacturers phasing out support and training programmes for older systems, waiting on parts and service may take days, resulting in downtime that impacts production completion and project delivery.

Leader in automation systems, offering modern CIJ technology with automation-powered features. For example, the MK-G Series features a component called the MK Dock, which automates maintenance tasks and processes that require user input in traditional CIJs, reducing the need for skilled labour.

This low-maintenance continuous inkjet printing solution has no service contracts. Users are not tied into monthly or yearly service fees nor required to depend on a technician for service and repairs.

An intuitive, touch-screen interface for easy setup, operation, and maintenance. The user is interactively guided through every task, and the user-friendly design makes it possible for anyone to operate, maintain, and troubleshoot the system.

The more complex maintenance tasks, including cleaning, diagnosis, and others, are fully automated. The auto‑shower function cleans all the critical areas in the print head, ensuring high print quality, and smooth reliable operation.

The self-diagnosis function monitors and guides cleaning operations, identifying and notifying about important information such as nozzle status, ink viscosity, and more. By detecting and correcting issues automatically, it greatly reduces reliance on skilled technicians.

Several complex steps are required to replace the nozzle in a traditional CIJ printer. First, you need to disconnect the ink supply and release the nozzle retaining mechanism. Often, 8 to 12 screws hold the printhead together, which you must unscrew to gain access to the internals of the printhead. From there, you’ll need to use needle-nose pliers to grip, twist, and remove the old nozzle and any other parts that could block access to it. Once the internals are exposed, you can proceed with replacing the costly nozzle and reassembling the printhead to return to normal operations. Even for skilled technicians, the process can take upwards of 30 minutes to complete and is quite costly.

In contrast to this lengthy, complex process, the KEYENCE One-Touch Nozzle Replacement simplifies this maintenance task. Our reliable inkjet printer will notify when the nozzle needs replacement, the illustrated touchscreen instructions will assist the user in completing the nozzle replacement with no tools required in approximately one minute. Simply remove the front cover of the printhead, take off the nozzle fastener, discard the old nozzle, and replace it with the new one.

Not only does this reduce downtime, but it is also cost-effective. The price of a high-grade, durable ceramic nozzle is only approximately one-tenth the cost of traditional CIJ nozzles.

Traditional CIJ printers require extensive training and specialised knowledge for proper maintenance. Some CIJ manufacturers often provide training programmes on how to troubleshoot and repair specific models. Training time could take weeks or extend to months.

With the MK-G Series automatic CIJ industrial inkjet printing machine, training time is almost non-existent. Illustrated instructions on the easy-to-use touchscreen interface walks the user through how to troubleshoot and complete maintenance operations. This process takes minutes, not hours or days.

Traditional CIJ printer maintenance involves many areas. The print head must be cleaned regularly, and the ink system and nozzles must be maintained. Monitoring ink levels, filter and pump replacement, and ink droplet calibration must also be addressed consistently.

Our industrial inkjet printers, with built-in self-diagnosis and troubleshooting functions can pinpoint exactly when cleaning is required and what part needs to be replaced. Cleaning is done automatically, and the one-touch, tool-free replacement of parts has simplified maintenance procedures. This simplified troubleshooting process reduces reliance on both internal and external technicians.

Print head maintenance and cleaning prevent clogs caused by dried ink in the nozzles. A clean print head also ensures precise ink droplet formation, which enhances print quality and consistency. In traditional CIJs, print head cleaning is a manual process that exposes the individual to chemicals and uses excess solvents. This process can take up to 30 minutes, depending on the severity of the clog.

The hands-free, auto-shower cleaning function of the MK-G Series CIJ uses a high-pressure jet stream of solvent to dislodge and remove dried ink, stubborn debris, or contaminants from critical components of the print head. This helps ensure the nozzle is not blocked and remains clear. After cleaning, the built-in blower automatically dries the head to complete the procedure. This makes for a consistent and reliable solution that uses the proper amount of solvent each time and reduces downtime due to cleaning.

This CIJ printing solution reduces wait times for parts or professional service. There is no extended lead times for ink or replacement parts ever. KEYENCE provides same-day shipping for all components, including new printers, with overnight delivery options available. This commitment has remained steadfast throughout the COVID-19 pandemic. In contrast, competitors often face lead times of two to three weeks or longer for parts or ink/solvents, leaving customers stranded with printers awaiting essential components.

Instructional videos and easy-to-follow onscreen instructions help all skill level employees perform maintenance and part replacement without hassles. Plus, the printer’s built-in monitoring function helps detect in real time what’s going on with every critical part of the system. There is no waiting for service, as the troubleshooting process can be initiated immediately with the press of a button. This ensures rapid recovery from issues that may arise when using quick-drying ink in CIJ printers.

For more information on the KEYENCE MK-G Series industrial inkjet printer, contact us today.