Flat-Edge vs Near-Edge printing: How to choose the best solution for your Print and Apply labeler
Two types of printhead technologies are commonly used on packaging lines that require a high-quality Print & Apply labeler suited to secondary and tertiary packaging such as cases, corrugated boxes, trays and pallets: flat-edge and near-edge technologies. Both can print high-quality barcodes and QR codes on self-adhesive labels, but there are some significant differences which must be considered to select the best solution for a specific system.
For instance, near-edge solutions can operate at higher line speeds than flat-edge solutions, and this is often presented as a key benefit. It is an advantage that can rarely be fully utilized in Print & Apply applications, however and comes with significantly higher Total Cost of Ownership (TCO). The reality is that for most businesses, flat-edge technology will be the most effective solution for any Print & Apply labeling system, ensuring optimal printing performance and minimizing TCO.
But to make an informed decision that maximizes short-term performance and long-term cost efficiency as a business moves into the renewal phase or considers upgrading its Print and Apply labeler, it is necessary to understand the key differences between these two technologies. In addition, businesses should assess whether the current solution is still aligned with operational needs, cost targets, and future production plans.
The difference between near-edge and flat-edge printheads
Near-edge and flat-edge technologies are both widely used in a variety of printing applications, and both can produce high-quality code when used for the applications they are best suited to.
Near-edge technology is the term given to solutions where the printhead is positioned at a sharp angle in relation to the ribbon and label. The advantage of this configuration is that the ribbon is in contact with the label for significantly less time, enabling printing speeds that typically can be up to 60% higher than flat-edge solutions. In general terms, near-edge printheads were designed and continue to be used primarily for Thermal Transfer Overprinting (TTO) applications, where high speed printing on flexible films is required.
The printhead in flat-edge solutions is positioned horizontally, so that the ribbon remains in contact with the label for longer, while passing the printhead. The principal advantage of the traditional flat-edge configuration is that it delivers the best possible print quality with high contrast sharp codes that are Grade A GS1-compliant. Crucially, flat-edge solutions also offer greater consistency across a wider range of substrates and label materials.
To simplify the decision-making process, three factors often cited as the most important for businesses considering upgrading or renewing their Print & Apply labeling system are examined in more detail below.
Improving line speed and operational efficiency
The high printing speed that near-edge solutions can provide is their main advantage, but it is rarely something which can be leveraged in Print and Apply applications, simply because the line speed will be limited by a range of other variable factors. These include the packaging process, the product spacing on the line, and the conveyor or the applicator. Throughput will therefore rarely increase as a result solely of using near-edge technology. In fact, while near-edge solutions can reach speeds of 150 packs per minute (ppm), these factors will typically prevent speeds of more than 65 ppm.
The reality is that flat-edged printers can print at the highest line speeds achievable in the majority of Print & Apply applications while there are very few situations in which the high-speed capability of near-edge solutions can be used.
But improving operational efficiency is not only reliant upon achieving the highest line speed possible. It is influenced by the reliability of the technology used, its typical maintenance requirements, likely downtime, and its complexity for operators.
Near-edge solutions run at a higher pressure and temperature than flat-edge printers, which means they require greater maintenance and normally results in a shorter printhead lifespan. The more abrasive surface of labels used on Print & Apply applications in comparison to TTO applications, will further reduce the printhead lifespan. The result is that near-edge printhead costs can be up to double those of flat-edge solutions for many businesses.
Coupled to this, there is the higher risk of unplanned downtime associated with near-edge solutions due to material-related stoppages and wear-related degradation that results in poor print quality. In addition, some near-edge solutions do not properly protect the ribbon from environmental factors such as the build-up of dust and adhesives. It is often the additional interventions, operator time and missed targets caused by these factors that will result in the most significant avoidable costs for businesses.
Another advantage which is often cited for near-edge solutions is that the printhead has a smaller gap between the front and back of the label which can maximize label space. While this offers a significant advantage for TTO applications, however, it is less relevant for Print & Apply and in most cases, back-feeding a flat-edge printer will offer the same advantage if required.
Flat-edge printheads which wear less quickly and offer a longer lifespan – Markem-Imaje customers often report double the distance compared to near-edge solutions – are therefore the more reliable option in industrial environments and key to improving operational efficiency.
Versatility: the key to future-proofing packaging lines
Material compatibility and versatility are two of the most significant differences between near-edge and flat-edge printing solutions.
Near-edge printheads, which are ideal for TTO applications, require higher-grade resin-enhanced ribbons, to achieve Grade A GS1 compliant labels. Typically, these high-grade ribbons are 20% more expensive than the standard wax/resin ribbons used by flat-head solutions.
Therefore, although near-edge technology will perform well in flexible film applications, for Print & Apply environments in which a wide variety of label materials are used, the high-grade ribbon requirement of near-edge solutions creates an additional and significant level of expenditure.
It is widely accepted that flat-edge solutions have greater tolerance to varying label coatings, adhesives, paper or synthetic labels and changes in ribbon grades. And for most businesses, the ability to achieve optimal print quality using a wide variety of labels and ribbons such as the Ultraply® consumables, provides greater flexibility, eliminating unnecessary cost without compromising print quality.
In addition, this flexibility means that flat-edge solutions are ideally suited to packaging operations which run multiple product lines or need to change label size frequently, as well those planning for line changes or expanding their operation.
Total Cost of Ownership (TCO)
All these factors contribute to what many businesses will regard as the most important factor when deciding on the most suitable print technology: TCO. And a range of factors should be considered when renewing or considering an upgrade, including the initial capital expenditure, spare parts, maintenance and downtime, label and material costs, ribbon costs, and the frequency at which printheads will need to be replaced.
For most business, near-edge printers are likely to have a higher TCO than flat-edge solutions as they offer less flexibility, require higher grade ribbons and higher specification label materials The higher cost of consumables, when considered over the lifetime of a near-edge printer will be substantial, and the initial purchase cost will be higher.
Flat-edge printers are less expensive, have lower running costs and typically last longer with fewer maintenance requirements. Their ability to operate at lower pressure and lower temperatures reduces wear, extending the printhead lifespan, while replacement printheads typically cost 15% less.
The best choice of printing technology for Print & Apply applications
Solutions such as the Markem-Imaje 2200 Series industrial labeler with the award winning eTouch-S® applicator are specifically designed to support flexible Print & Apply systems, helping businesses to future-proof their operation and retain their competitive advantage.
The table below provides a useful starting point for businesses considering an upgrade and those which are in the early stages of the renewal process.
At a glance:
| Application | Ideal for: | |
| Near-edge | Flat-edge | |
Barcodes, shipping, and warehouse labels | ✓ | ✓ |
| Paper and synthetic substrates | ✓ | ✓ |
| Cost-sensitive operations | - | ✓✓ |
| High-speed production lines | ✓✓ | ✓ |
Food packaging, pharma, or flexible films | ✓ | ✓ |
| - | Not recommended |
| ✓ | Suitable / Recommended |
| ✓✓ | Best choice / Highly recommended |
But there is no one size fits all, or ‘best’ solution – the correct choice will always depend entirely upon the application. To make the correct decision, having evaluated the pros and cons of near-edge and flat-edge solutions, business should establish which factors are most important to their operation and which if any, are likely to change in future.
These factors will include the initial cost, operating environment, maintenance requirements, future plans and the need for flexibility, and the cost of consumables as well as expected and unplanned downtime.
FAQs
What are the four main types of labeling?
The four main types of applicators for a print and apply labeler are:
Blow applicator
A Blow applicator works by feeding the label from the printer onto a vacuum grid and blowing it across the void onto the product with a jet of air.
Tamp-Blow applicator
Tamp-Blow are generally the same technology as Tamp, where an electrical or air-driven linear actuator is used to advance the label and directly contact the product.
The only difference between them is that with Tamp-Blow, the applicator moves out to get as close as possible to the product, without making contact, and blows the label using air onto the product surface.
Synchronous Feed applicator
As the name suggests, a Synchronous Feed applicator is synchronized to the speed of the product or the conveyor.
Wipe applicator
The Wipe applicator works by taking the label and then feeding it onto a rotating arm. It is suited for a multitude of applications from single side apply to multiple surfaces, including front or rear-end surfaces, or a combination.
Find out more about the benefits of each type of labeling system.
Where can I find affordable industrial-strength labeling solutions?
Markem-Imaje provides a wide range of applicators for a range of sizes, products and packaging types, minimizing the need for line changes and expensive modifications. Our print and apply options have a proven track record of increasing uptime and provide highest quality and most reliable printing of all available technologies, giving “A” grade GS1 compliant barcodes. Safe and easy to use, Markem-Imaje industrial labelers feature distinctive technologies that will help you achieve great cost of ownership through maximum production uptime, high performance, and minimum downtime.
Why is labeling important?
Accurate and efficient, high-quality labeling is a fundamental requirement for a successful packaging operation. Effective labeling solutions help to ensure regulatory compliance and reduce errors, waste and running costs, contributing directly to a more efficient and profitable operation. The continued increase in automation, traceability, and security requirements means that the demand for reliable, high quality labeling solutions will become even greater in the years ahead.
