Choosing the Right Industrial Inkjet Printer: A Complete Guide to CIJ, TIJ and DOD Technologies
Choosing the Right Industrial Inkjet Printer: A Complete Guide to CIJ, TIJ and DOD Technologies
Date: January 14, 2026
Subject: Industrial Coding and Marking Optimization
Prepared for: USInks.com
Abstract
The modern production line relies heavily on the integration of secondary and primary packaging coding to ensure traceability, regulatory compliance, and brand integrity. This paper examines the three dominant inkjet technologies currently utilized in industrial settings: Continuous Inkjet (CIJ), Thermal Inkjet (TIJ) and Drop-on-Demand (DOD). By analyzing the mechanical operations, substrate compatibility, and maintenance profiles of each, manufacturing managers can better align their technology hardware with their specific throughput requirements and optimize their total cost of ownership.
Introduction
Industrial inkjet printing has evolved from simple character marking to complex data serialization. As global supply chains demand higher levels of transparency, the choice of coding technology becomes a strategic decision. The efficiency of a production facility is often measured by its uptime, making the reliability of the chosen inkjet system a primary variable in operational success.
I. Continuous Inkjet (CIJ)
Continuous Inkjet technology is characterized by its ability to print at extreme velocities. The system works by pumping liquid ink from a reservoir to a nozzle, where piezoelectric crystals break the stream into individual droplets. These droplets are electrostatically charged and deflected to form characters on the substrate.
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Operational Dynamics: CIJ is unique because the ink stream is constant. Droplets not used for printing are captured by a gutter and recirculated.
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Application: This is the preferred method for high-speed primary packaging, such as bottling and canning, where the substrate may be curved or irregular.
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Limitations: Because the ink is exposed to the air during recirculation, solvents evaporate, requiring the constant addition of "makeup" fluids to maintain proper viscosity.
LEIBINGER JET2JNEO CIJ Printer
II. Thermal Inkjet (TIJ)
Thermal Inkjet systems operate on a simpler mechanical principle. A heating resistor within the ink chamber creates a steam bubble, which expands to eject a droplet through the nozzle. This technology is often referred to as "bubble jet" printing.
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Operational Dynamics: TIJ systems are typically cartridge-based. Each time a cartridge is replaced, the user effectively installs a new printhead.
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Application: TIJ is the industry standard for high-resolution 2D DataMatrix codes and pharmaceutical serialization. It provides the highest print quality, reaching up to 600 DPI.
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Limitations: TIJ has a very short "throw distance," meaning the printhead must remain within 1 to 5 millimeters of the product to ensure accuracy.
Squid Ink Viper TIJ Printer
Norwix UC22 TIJ Printer
III. Drop-on-Demand (DOD)
Large-character Drop-on-Demand (DOD) printers, specifically Valve-jet systems, use a series of independent valves to release ink only when a pulse is received.
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Operational Dynamics: Unlike CIJ, DOD only ejects ink when it is time to print. This makes the system mechanically simpler and highly robust.
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Application: DOD is most frequently used in heavy industry and secondary packaging. It is ideal for printing large logos, batch numbers, or text on porous surfaces like lumber, gypsum board, or corrugated shipping containers.
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Limitations: The resolution is significantly lower than TIJ or CIJ, making it unsuitable for small-scale primary product marking.
Squid Ink CoPilot LT "Long Throw" DOD/Piezo Printer
Comparative Analysis Summary
| Criteria | Continuous Inkjet (CIJ) | Thermal Inkjet (TIJ) | Drop-on-Demand (DOD) |
| Primary Use | High-speed primary packaging | High-res barcodes/labels | Large boxes/Heavy industry |
| Max Resolution | Low to Moderate | High (600 DPI) | Low (Macro) |
| Maintenance | High (Internal fluids) | Minimal (Cartridge-based) | Moderate (Rugged) |
| Typical Substrate | Non-porous (Plastic, Metal) | Porous/Coated Paper | Porous (Wood, Corrugate) |
Recommended USInks Solutions by Technology
To achieve peak performance and extend the life of your equipment, it is essential to use high-grade inks formulated specifically for your printer's delivery method. Below are the recommended ink types for each technology.
| Technology | Recommended Ink Type | Best Applications | Why it Works |
| Continuous Inkjet (CIJ) | Solvent-Based Fluids & Makeup | Plastic bottles, aluminum cans, wire/cabling | High-adhesion formulas designed for rapid drying on non-porous surfaces at high speeds. |
| Thermal Inkjet (TIJ) | Solvent & Aqueous Cartridges | Pharmaceutical boxes, high-res barcodes, pouches | Self-contained cartridges prevent mess; available in water-based for paper or solvent for slick foils. |
| Drop-on-Demand (DOD) | Large Character Oil/Propanol Inks | Corrugated shipping cases, lumber, gypsum board | Formulated for high-contrast visibility on absorbent surfaces; resistant to fading and bleeding. |
Conclusion
The selection of an inkjet technology must be dictated by the substrate material and the environment of the production floor. CIJ remains the leader for speed and versatility on irregular surfaces. TIJ offers a maintenance-free, high-resolution solution for flat packaging. DOD provides the durability required for large-scale industrial marking. For all three technologies, the chemical compatibility of the ink remains the most critical factor in achieving long-term print legibility and system longevity.
Sources and References
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Industrial Coding and Marking Systems. (2024). Principles of Non-Impact Printing. TechPress Manufacturing Series.
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International Journal of Inkjet Printing. (2023). Comparative Analysis of Solvent-Based vs. Aqueous Inks in CIJ Systems.
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USInks Technical Documentation. (2025). Substrate Compatibility and Adhesion for TIJ and DOD Applications. usinks.com/technical-guides.
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Packaging Strategies Magazine. (2023). The Rise of Serialization: Why TIJ is Dominating Pharma Packaging.
Frequently Asked Questions: Industrial Inkjet Coding
Q: What is the main difference between CIJ and TIJ printers? A: The primary difference lies in maintenance and resolution. CIJ (Continuous Inkjet) is designed for high-speed, 24/7 production on curved or irregular surfaces but requires regular maintenance of its fluid system. TIJ (Thermal Inkjet) is virtually maintenance-free and offers much higher print resolution (up to 600 DPI) but requires the printhead to be very close to the product.
Q: Can I use TIJ printers on non-porous surfaces like plastic or metal? A: Yes, provided you use the correct solvent-based ink cartridges. While TIJ was traditionally for porous materials like paper and cardboard, modern solvent inks allow TIJ systems to code effectively on plastics, films, and foils.
Q: When should I choose DOD (Drop-on-Demand) over CIJ? A: Choose DOD if you need to print large characters (typically over 1 inch tall), logos, or batch codes on secondary packaging like corrugated shipping boxes or construction materials. DOD is more cost-effective for large-scale markings in rugged, dusty environments where high resolution isn't required.
Q: Why is "makeup fluid" necessary for CIJ printers? A: In a CIJ system, ink is constantly recirculated and exposed to air. This causes the solvent to evaporate, thickening the ink. Makeup fluid (solvent) is automatically added by the printer to maintain the correct viscosity for consistent printing.
Q: Which inkjet technology has the lowest total cost of ownership (TCO)? A: For low-to-medium volume lines, TIJ usually has the lowest TCO because it requires no professional servicing or replacement parts—you simply replace the cartridge. For extremely high-volume, 24/7 lines, CIJ often becomes more cost-effective per-print despite the higher maintenance costs.
The USInks Advantage
At USInks.com, we don't just provide fluids; we provide compatibility. Our inks are engineered to meet or exceed OEM specifications, ensuring that your CIJ, TIJ or DOD system maintains maximum uptime without the premium "brand name" price tag.