Digital label production at PFS focuses on reducing the total cost per label by eliminating traditional tooling requirements. We offer two distinct technology paths: IntoPrint for high-opacity white toner applications and Afinia Label for high-speed, low-cost inkjet production.
Label Printing Technology Comparison
1. IntoPrint RP530W (Specialty Toner Series) The RP530W is a narrow-web digital press designed for high-margin specialty labels that require white ink or extreme durability.
- White Toner Capability: Utilizing LED dry toner technology, the RP530W prints CMYK+W in a single pass, enabling vibrant graphics on clear, metallic, and dark wood-grain stocks.
- Variable Data: Fully supports variable printing for serialized barcodes, nutritional facts, and personalized branding.
- Maintenance Efficiency: Unlike inkjet systems, dry toner does not settle or clog, eliminating the need for daily printhead cleaning cycles.
- Format: Optimized for a 5.12-inch web width with a production speed of 10 feet per minute.
2. Afinia Label (High-Speed Inkjet Series) Afinia systems utilize Memjet "Waterfall" technology to deliver industrial speeds and the lowest ink cost per label in the category.
- Afinia L901 (Industrial): Engineered for 24/7 inline production, the L901 prints at speeds up to 12 inches per second (60 ft/min) with a maximum width of 8.5 inches.
- Watershield™ Technology: The "Plus" models use specialized pigment inks that provide superior water and UV resistance, essential for chilled beverages and chemical labeling.
- Afinia L801 (Commercial): A high-capacity tabletop solution featuring 1.25-liter ink tanks to support long production runs without operator intervention.
- On-the-Fly Maintenance: The L901 print engine can service the printhead mid-job, preventing downtime during massive roll-to-roll production.
Digital Label Finishing (No-Die Workflow)
Printing is only half the process; PFS Graphics provides digital finishers that eliminate the $200–$500 cost of physical dies.
- Afinia DLF-220S: A plotter-style finisher that uses a digital cut file to contour-cut any shape. It performs unwinding, laminating, waste removal, slitting, and rewinding in a single consolidated process.
- IntoPrint RF8510: A complementary finisher for the RP series, supporting web widths up to 8.5 inches and speeds up to 13 feet per minute with single-point registration for precision cutting.
Solving Label Production Failure Points
Q: How do I choose between toner (IntoPrint) and inkjet (Afinia)? A: Select IntoPrint if your primary applications involve dark/transparent media requiring white ink or if you have intermittent production schedules where inkjet heads might clog. Select Afinia if your primary goal is the lowest possible cost per label on standard white paper or BOPP film at high volumes.
Q: Can I print waterproof labels for the craft beer or wine industry? A: Yes. Use the Afinia L901 Plus with Watershield™ inks or the IntoPrint RP530W with its inherently waterproof dry toner. Both systems produce labels that withstand moisture and abrasion when paired with the correct synthetic media.
Q: What is the ROI of a digital finisher over buying pre-die-cut labels? A: Buying pre-die-cut rolls forces you to stock multiple sizes and limits you to standard shapes. A digital finisher (DLF-220S or RF8510) allows you to buy "continuous" master rolls—which are 20-30% cheaper—and cut custom shapes on demand, effectively paying for the hardware through substrate savings within 12–18 months.
Technical Specification Matrix
|
Feature |
IntoPrint RP530W |
Afinia L801 |
Afinia L901 |
|---|---|---|---|
|
Max Speed |
10 ft/min |
60 ft/min |
60 ft/min |
|
Ink/Toner Type |
LED Dry Toner (CMYK+W) |
Dye-based Inkjet |
Aqueous Pigment (Watershield) |
|
Max Resolution |
1200 x 1200 dpi |
1600 x 1600 dpi |
1600 x 1600 dpi |
|
Max Web Width |
5.12 Inches |
8.5 Inches |
9.0 Inches |
|
Best For |
White ink / Specialty media |
Short-run prime labels |
High-volume inline production |
Critical Risk Assessment
While Afinia’s Memjet technology offers the best speed-to-cost ratio, the printheads are considered a consumable item; failure to perform regular maintenance can lead to premature head replacement costs. IntoPrint systems have higher toner costs but offer "plug-and-play" reliability for shops that may go days between label jobs. Furthermore, digital plotter-cut finishing is slower than rotary die-cutting; for jobs exceeding 10,000 linear feet, the finishing process will become the primary production bottleneck.
