The core idea of this page: the three coding technologies differ in what they mark, how long the mark lasts, and what they cost to run. CIJ sprays ink, TTO melts ribbon onto film, laser changes the surface itself. Pick by substrate and durability requirement first, then by consumable cost and maintenance.
The comparison at a glance
| Dimension | CIJ (continuous inkjet) | TTO (thermal transfer overprint) | Laser |
|---|---|---|---|
| How it marks | Charged ink droplets deflected onto the surface | Ribbon melted onto the substrate | Surface ablated, foamed or colour-changed by a beam |
| Best substrates | Cartons, glass, PET, cans, cable, most rigid surfaces | Flexible film and laminates, labels, pouches | PET, glass, coated cartons, some films with additives |
| Durability | Moderate; solvent-removable, can smear on some surfaces | Good; bonded to the film, survives most handling | Permanent; part of the material |
| Resolution | Low to moderate; fine text and 2D codes need care | High; crisp small text and dense 2D codes | High; fine detail and codes are a strength |
| Consumables | Ink and solvent — ongoing, with disposal rules | Ribbon — ongoing, simple disposal | None; electricity only |
| Maintenance | Highest: printhead cleaning, nozzle purge, solvent top-up | Moderate: printhead and ribbon path cleaning | Low: lens and extraction checks |
| Line integration | Non-contact; fits most lines | Requires the film to pass the printhead with controlled tension | Requires guarding and extraction; alignment is critical |
| Relative running cost | Moderate to high (ink, solvent, service) | Moderate (ribbon, depends on code area) | Low after capital |
| Typical fit | Date and lot codes on rigid packs at speed | Flexible packaging lines, pouches, sachets, labels | High-volume, permanent marking on rigid packs |
How to decide
Substrate decides more than cost
Laser needs a surface that reacts; most clear films and many laminates simply do not mark, or mark so weakly that the code rubs off. On flexible film, TTO is usually the only reliable option. On glass, PET and coated cartons, laser is viable and eliminates consumables.
Durability requirement comes second
If the code must survive washing, freezing, abrasion or solvent contact, laser is the strongest, TTO next, CIJ last. Where the code is read once at packing and never handled again, CIJ is often sufficient.
Decision rules that hold up in practice
Flexible film, pouches, sachets: TTO.
Glass or PET bottles, high volume, permanent code wanted: laser.
Cartons, cans, mixed rigid substrates, low capital: CIJ.
Multiple substrates on one line: TTO or CIJ, because laser cannot mark them all.
Solvent restrictions or no-consumable policy: laser, accepting higher capital.
2D codes at small size on film: TTO, because CIJ resolution is marginal.
Cost, and where it hides
CIJ has the lowest capital and the highest running cost: ink, solvent, printhead service and disposal of solvent waste. TTO has moderate capital and a running cost proportional to printed area — large codes on large packs consume ribbon quickly. Laser has the highest capital and the lowest running cost, but adds extraction and guarding. Compare total cost over five years at your actual code area and line speed, not at the vendor's sample.
Failure modes worth designing out
CIJ fails through blocked nozzles, dried ink and drift in drop placement — usually discovered as unreadable codes at the end of a shift. TTO fails through ribbon wrinkles, printhead wear and film tension variation, producing partial or smeared codes. Laser fails through focus drift, dirty lenses and extraction faults. All three fail invisibly unless codes are verified by a reader rather than by an operator's eye.
Verification checklist
Confirm: substrate trial with the actual film, glass or carton before purchase; code verification with a reader, not just visual; ribbon or ink consumption measured per thousand packs; maintenance schedule and spare printheads defined; extraction and guarding for laser; and a documented retest after any substrate change.
Source: Thermal-transfer printing — Wikipedia
"Thermal-transfer printing is a digital printing method in which material is applied to paper (or some other material) by melting a ribbon coating so it stays glued to the material on which the print is applied."
Frequently asked questions
Can laser code flexible film?
Only films formulated to react to the beam. Most clear and metallised laminates either do not mark or mark weakly, so trial before specifying.
Is CIJ being replaced by TTO?
On flexible packaging, largely yes. On rigid packs, CIJ remains common because it is cheap to install and works on curved surfaces.
Which has the lowest cost per code?
Laser, once the capital is written off, because it has no consumables. CIJ usually has the highest cost per code at volume.
Related reading: how a pressure-sensitive labeler works, in-line vs standalone inspection, and the labeling and coding category.
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