Industrial Coding and Marking Technologies for Pharmaceutical Packaging
Industrial Coding and Marking Technologies for Pharmaceutical Packaging
A Practical Guide to CIJ, TIJ and DOD Piezo Systems, Fluids and Deployment
Executive Summary
Pharmaceutical packaging lines are being asked to do more with less: higher throughput, tighter quality standards, more data per code, more verification points and more audit scrutiny. Coding and marking is no longer a minor accessory. It is a core control point that affects compliance, traceability, brand protection and overall equipment effectiveness.
This white paper explains the three most common non-contact coding technologies used in modern packaging operations: Continuous Inkjet (CIJ), Thermal Inkjet (TIJ) and piezoelectric Drop-on-Demand (DOD) inkjet. It describes how each technology works, where each performs best on pharmaceutical substrates and line configurations and how consumables influence reliability and code quality. It then connects those principles to practical system families often deployed in regulated environments, including CIJ printers, DOD piezo systems and TIJ printers. Finally,it provides a framework that packaging engineering, operations, quality and procurement teams can use to reduce downtime, improve scan rates and future-proof their coding strategy.
Key takeaways:
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CIJ is the workhorse for high-speed primary coding on varied substrates, especially where uptime and flexibility matter most
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TIJ is a strong fit for secondary packaging and high-resolution 1D and 2D codes, especially where cartridge or bulk-cartridge workflows simplify maintenance
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DOD piezo excels in high-visibility secondary and tertiary coding where larger print heights, longer throw-distance and bold marks are needed
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Inks and solvents are not just supplies, they are performance variables that directly affect drying time, adhesion, contrast, maintenance intervals and code verification grades
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A technology decision should be made around substrate, line speed, code content, environmental conditions and verification requirements, not around specs alone
1. Why coding and marking matters in pharmaceutical packaging
Pharmaceutical packaging is driven by control, traceability and repeatability. Codes must remain readable throughout distribution, storage and dispensing, even after exposure to abrasion, condensation, handling and variable temperatures. In many environments the same line may run multiple SKUs, multiple pack formats and multiple materials, requiring fast changeovers without sacrificing print quality.
Two trends are raising the stakes. First is increased data density, including broader adoption of GS1 2D symbols such as GS1 DataMatrix and GS1 Digital Link to support serialization, traceability and downstream digital access. Second is increased verification scrutiny, with ISO-based grading methods used to assess symbol quality and ensure readability across the supply chain.
The practical result is that print quality, consistency and repeatability matter as much as the ability to place a code on a package.
Pharmaceutical Packaging Level Mapping
| Packaging Level | Typical Products | Primary Coding Needs | Best-Fit Technology |
|---|---|---|---|
| Primary | Vials, bottles, blisters | Date, lot, batch, small characters | CIJ |
| Secondary | Cartons, labels, bundles | High-resolution text, 1D and 2D codes | TIJ |
| Tertiary | Cases, trays, pallets | Large characters, logistics codes | DOD Piezo or TIJ Case Coding |
2. Technology overview: CIJ, TIJ and DOD piezo
2.1 Continuous Inkjet (CIJ)
CIJ systems generate a continuous stream of ink droplets that are electrically charged and deflected to form characters on the substrate. Unused droplets are recirculated back into the ink system. This approach allows CIJ printers to operate at very high speeds and to print reliably on moving targets, curved surfaces and irregular substrates.
CIJ inks are typically solvent-based and engineered to dry rapidly, which makes solvent management and viscosity control central to stable operation. If solvent balance is not maintained, viscosity drift can affect droplet formation, character definition and long-term print quality. As a result, CIJ performance is inseparable from both the printer architecture and the ink and solvent system supporting it.
2.2 Thermal Inkjet (TIJ)
TIJ systems eject droplets on demand by rapidly heating ink in a firing chamber to create a vapor bubble that propels ink through the nozzle. In industrial settings, TIJ is valued for high-resolution output, clean operation and simplified maintenance models.
TIJ systems are commonly deployed for secondary packaging applications where flat surfaces and controlled presentation allow consistent placement of high-density information. Cartridge-based or bulk-cartridge workflows reduce operator intervention but increase the importance of proper ink selection and handling procedures.
2.3 Piezoelectric Drop-on-Demand (DOD piezo)
Piezo DOD systems use an electrical impulse to deform a piezo element, forcing a droplet of ink through the nozzle only when required. Because no heat is used, piezo DOD supports a broader range of ink chemistries, including more viscous and high-contrast formulations.
This technology is widely used for secondary and tertiary packaging, particularly where long throw-distance, larger print heights and high-visibility marks are required.
2.4 Coding Technology Comparison for Pharmaceutical Packaging
| Technology | Packaging Level | Print Detail | Throw Distance | Speed Capability | Maintenance Model |
|---|---|---|---|---|---|
| CIJ | Primary | Small character, dense data | Short to medium | Very high-speed | Solvent management, periodic cleaning |
| TIJ | Secondary | High-resolution text and 2D | Short | Medium to high-speed | Cartridge or bulk-cartridge replacement |
| DOD Piezo | Secondary, tertiary | Large characters, bold codes | Medium to long | Medium-speed | Minimal cleaning, ink-specific upkeep |
3. Printer family considerations aligned to real-world production
3.1 CIJ printers and restart reliability
| Condition | Conventional CIJ | Sealed-Nozzle CIJ |
|---|---|---|
| During downtime | Nozzle exposed to air | Ink circuit sealed |
| Dry-out risk | High | Low |
| Cleaning required | Frequent | Minimal |
| Restart print quality | Often inconsistent | Consistent from first print |
A common challenge in CIJ printing is nozzle dry-out during production stops, breaks or weekend shutdowns. Designs that isolate ink from air during downtime significantly reduce dry-out, improve first-print quality and lower operator intervention.
3.2 CIJ systems for small character coding
Small character CIJ platforms remain a core technology for primary pharmaceutical packaging due to their ability to print at high-speed on curved, moving and variable surfaces.
3.3 DOD piezo for secondary and tertiary packaging
| Technology | Typical Print Height | Typical Throw Distance | Common Applications |
|---|---|---|---|
| CIJ | Small characters | Short to medium | Bottles, vials |
| TIJ | Medium characters | Short | Cartons, labels |
| DOD Piezo | Large characters | Long | Cases, pallets |
DOD piezo systems are selected when print visibility, durability and placement tolerance are more critical than compact printhead size.
3.4 TIJ systems for cartons and cases
High-resolution TIJ systems are commonly deployed on cartons and cases where controlled presentation allows consistent barcode quality and high verifier grades.
3.5 TIJ systems for regulated environments
TIJ platforms using cartridge-based consumables are often selected in regulated environments due to their predictable maintenance behavior and reduced need for daily cleaning routines.
4. The overlooked variable: Inks and solvents
Inks and solvents are functional components of the printing system, not just consumables. In pharmaceutical environments, fluid selection directly affects dry-time, adhesion, contrast, rub resistance and long-term code durability.
Ink, Substrate and Environment Interaction Model
| Variable | Impact on Print |
|---|---|
| Printer technology | Droplet size, placement accuracy |
| Ink chemistry | Dry-time, adhesion, contrast |
| Substrate | Absorption, surface energy |
| Environment | Smearing risk, evaporation rate |
| Result | Scan rate, verification grade |
Improper ink selection can lead to smearing at speed, poor adhesion on low-energy plastics, excessive dot gain on porous materials or premature fading. Solvent volatility, pigment load and binder chemistry must be evaluated in the context of both substrate and production environment.
5. Code quality, verification and 2D readiness
As pharmaceutical packaging adopts higher data density codes, verification becomes a primary control mechanism rather than an afterthought. GS1 DataMatrix and similar symbols are evaluated using ISO-based grading methodologies that assess contrast, modulation, axial non-uniformity and grid distortion.
Printer resolution alone does not guarantee acceptable grades. Ink chemistry, substrate interaction and environmental conditions all influence symbol quality. Consistent verification performance requires testing at production speed using actual materials, followed by ongoing monitoring to detect drift over time.
6. Implementation best practices
Successful implementation begins with clearly defined compliance targets, including acceptable verification grades and rework thresholds. Technologies and consumables should be validated under worst-case conditions, including maximum line speed, temperature variation and humidity.
Standardizing inks and solvents across lines reduces variability and simplifies training, documentation and audits. Preventive maintenance schedules should be aligned with actual fluid behavior rather than calendar intervals alone. Verification systems should be integrated into routine production workflows to provide continuous feedback rather than post-run inspection.
Conclusion
Selecting a coding and marking solution for pharmaceutical packaging is not a hardware decision, it is a system-level engineering decision. Continuous Inkjet, Thermal Inkjet and Drop-on-Demand piezo technologies each serve distinct roles across primary, secondary and tertiary packaging, and none can be evaluated in isolation.
High-speed primary coding demands flexibility, fast dry-times and restart reliability. Secondary packaging requires high-resolution output and consistent verification performance. Tertiary packaging prioritizes visibility, durability and tolerance to variable presentation. Across all three, inks and solvents act as performance drivers that directly influence uptime, compliance and total cost of ownership.
Organizations that approach coding as an integrated system, combining technology selection, fluid chemistry, maintenance strategy and verification methodology, achieve more consistent performance, lower reject rates and stronger audit readiness. As regulatory requirements evolve and data density increases, this system-level approach is essential for maintaining both compliance and operational efficiency.
References
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https://www.leibinger-group.com/en/technology/nozzle-seal/ -
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https://www.gs1.org/standards/gs1-datamatrix -
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