Extending Equipment Life: Best Practices for CIJ, TIJ and DOD/Piezo Printers

Extending Equipment Life: Best Practices for CIJ, TIJ and DOD/Piezo Printers

Executive Summary

Continuous Inkjet (CIJ), Thermal Inkjet (TIJ) and Drop on Demand (DOD) Piezo printers are essential technologies for modern packaging lines. They apply critical product codes, barcodes and traceability information that keep supply chains compliant and efficient. With proper maintenance these printers provide years of dependable service. When neglected they become a source of downtime, repairs and lost productivity.

This paper explores the pitfalls that shorten printer life, explains how proper use of inks and solvents prevents damage and outlines cost saving maintenance schedules. It provides specific recommendations for LEIBINGER CIJ printers, Norwix TIJ printers using HP cartridge technology and Squid Ink high-resolution DOD/Piezo systems including the CoPilot and Viper series that use Xaar and Funai technology.

Common Pitfalls That Cause Downtime

Unplanned downtime in CIJ, TIJ and DOD systems disrupts throughput and can cost thousands of dollars per hour (Moss and Pattison 2021).

The most common pitfalls include

  • Nozzle clogs from dried ink or improper flushing

  • Idle periods without proper shutdown that allow ink to harden in lines

  • Non compatible solvents that damage seals and valves

  • Neglected filters that reduce ink pressure and starve printheads

  • Harsh environmental exposure such as heat, dust and humidity

LEIBINGER identifies nozzle drying and ink contamination as leading causes of CIJ downtime, both preventable with correct procedures and fluids (Leibinger Group).

The Role of Inks and Solvents in Printer Life

  • Formulation compatibility: OEM and verified compatible inks protect tubing, pumps and seals from chemical attack. Kao Collins notes that off brand inks often alter viscosity and cause clogging or permanent head damage (Kao Collins 2020).

  • Solvent effectiveness: Correct cleaners dissolve residue without damaging coatings or elastomers.

  • Evaporation control: CIJ make up must maintain consistent evaporation rates to ensure stable drop formation.

  • Corrosion resistance: Specialty fluids prevent rust and corrosion in stainless steel and aluminum components.

Technology Specific Best Practices

Squid Ink High-Resolution DOD/Piezo Systems (CoPilot and Viper using Xaar technology)

These systems use Xaar piezoelectric printheads to deliver large, high-resolution characters and barcodes directly onto corrugated cases.

  • Use approved high-resolution inks to prevent particle buildup and protect piezo elements

  • Keep bulk ink systems sealed and filtered to prevent debris from entering the head

  • Flush lines during long idle periods to avoid nozzle edge drying

  • Replace filters proactively to ensure stable pressure and consistent drop placement

Norwix TIJ Printers (HP Cartridge Technology)

Norwix TIJ systems use HP thermal inkjet cartridges for high-resolution unit coding and serialization.

  • Use verified TIJ inks to protect heater resistors and prevent kogation that thickens residue on cartridges

  • For multi lane systems align maintenance to the lane with the highest duty cycle

  • Cap cartridges immediately when removed to prevent nozzle dry out

  • Store cartridges in sealed packaging when not in use to preserve nozzle integrity

Squid Ink Viper TIJ Printers (Funai Cartridge Technology)

The Viper TIJ uses Funai cartridge printheads optimized for 600 dpi codes.

  • Use Funai-compatible inks to ensure clean drop ejection and prevent heater burnout

  • Replace cartridges before end-of-life print quality issues appear

  • Clean only with approved wipes and solvents to prevent damage to cartridge seals and plastics

  • Monitor line speeds and substrate compatibility to maximize cartridge yield and reduce consumable costs

LEIBINGER CIJ Printers

LEIBINGER CIJ printers use Sealtronic nozzle sealing to prevent ink drying when idle.

  • Always park the head to activate Sealtronic during downtime

  • Use specified inks and make up to maintain proper viscosity and charge stability

  • Replace filters on schedule to protect pumps and valves

  • Clean overspray and dust near the nozzle and electrodes to maintain print accuracy

  • Monitor operating environments to prevent excessive evaporation at the nozzle tip

Cost Saving Maintenance Schedules

Daily

  • Inspect codes for clarity and scan performance

  • Wipe heads with approved solvent wipes

  • Check ink and solvent levels and confirm viscosity

Weekly

  • Flush CIJ and DOD systems if idle or operating in hot conditions

  • Replace clogged filters

  • Verify serialization, lot and date templates for accuracy

Quarterly or Semiannual

  • Replace inline filters proactively

  • Inspect tubing, pumps and seals for leaks or wear

  • Calibrate throw distance and head alignment

Annual

  • Perform a full system flush with OEM cleaning solutions

  • Replace long life filters and service kits

  • Audit logs for downtime, environmental exposure and consumable use to plan next year’s maintenance

Preventive maintenance can reduce total cost of ownership by up to 30 percent compared to reactive servicing (Matthews Marking Systems 2019).

The Downtime Advantage of Preventive Maintenance

Downtime is one of the most visible costs of poor maintenance. Studies show that preventive maintenance practices dramatically reduce unplanned stoppages (Matthews 2024).

Illustrative Impact of Preventive Maintenance on Downtime

  • CIJ (Leibinger): ~120 hours before, ~40 after

  • TIJ (Norwix HP + Squid Ink Viper Funai): ~95 hours before, ~30 after

  • DOD/Piezo (Squid Ink Xaar): ~105 hours before, ~35 after

Structured maintenance directly translates into higher uptime, smoother production and lower cost of ownership.

Conclusion

CIJ, TIJ and DOD/Piezo printers are durable when paired with correct fluids and disciplined care. The most common causes of downtime such as clogs, poor solvents, neglected filters and improper shutdowns are preventable.

  • Squid Ink CoPilot and Viper high-resolution printers (Xaar Piezo) require verified inks, sealed bulk handling and timely flushing

  • Norwix TIJ (HP cartridge based) systems deliver consistent serialization when cartridges are handled correctly and paired with compatible fluids

  • Squid Ink Viper TIJ (Funai cartridge based) delivers sharp codes and reliable cartridge life when paired with Funai-compatible inks

  • LEIBINGER CIJ printers achieve clean starts and reliable codes when Sealtronic is engaged and filters are replaced on schedule

By sourcing OEM and compatible consumables from USINKS.com and following structured maintenance, manufacturers extend printer life, reduce downtime and protect ROI.

References

Kao Collins. “Risks of Using Third Party Ink Cartridges.” Kao Collins, 2020. https://www.kaocollins.com/inktank/risks-of-using-third-party-ink-cartridges

Leibinger Group. “Continuous Inkjet Printers and Automatic Nozzle Sealing.” Leibinger. https://leibinger-group.com/cij-printer

Matthews Marking Systems. “The ROI of Preventive Maintenance for Inkjet Printers.” Matthews Marking, 2019. https://matthewsmarking.com

Matthews Australasia. “The True Cost of Downtime and How to Minimise It.” Matthews, 2024. https://www.matthews.com.au/blog/the-true-cost-of-downtime-and-how-to-minimise-it

Moss T, Pattison J. “The Hidden Costs of Downtime in Manufacturing.” Manufacturing Global, 2021. https://manufacturingglobal.com

Norwix. “TIJ 4.0 Driver Solutions and PC22 Specifications.” Norwix. https://norwix.com/tij4-driver-solutions and https://norwix.com/wp-content/uploads/2023/02/PC22_0922_c.pdf

Squid Ink. “CoPilot High Resolution Case Coding Solutions.” Squid Ink. https://squidink.com/products/hi-resolution-printers/copilot

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