Sophie Matthews-Paul reports on the capabilities of this UV-curable printer, designed specifically for the production of traffic and safety signs.
With diversification and niche production opportunities now being sought by wide-format print service providers, manufacturers are seeking areas where their existing technologies can be adapted to suit new market needs. One such example lies with the Mutoh Zephyr, in itself a perfectly acceptable UV-curable machine, which has been modified so that it can now be used for the production of high quality road traffic and safety signs. This version is designated the Zephyr TS and incorporates modified UV-curable inks to cater for the specific requirements of this sector.
One of the idiosyncrasies of traffic sign production is the vital role played by retro-reflectivity. Everyone is aware that these displays carry an essential dual function of being clearly visible during the day as well as throughout the night. A standard UV-curable ink-set is unable to provide the standards needed.
The reflective nature of these signs is reliant on the construction of the material and its coating as well as the manner in which the ink is put down, along with the correct levels of translucence. Not surprisingly there are strict regulations which need to be met in terms of visibility and the colours that are permitted in these displays. The Department of Transport’s website offers a host of manuals which cover every conceivable variant that comes under the heading of traffic signs, including regulatory and warning notices, along with official templates.
Compliance with the standard for fixed vertical road traffic signs means adhering strictly to EN 12899-1:2007 and this takes into account colours and weatherability as well as retro-reflectivity. As no ordinary CMYK ink configuration is able to meet these criteria, Mutoh’s Zephyr TS is the result of comprehensive development and testing to achieve the conformity required.
With so many variants required in the production of traffic signs, it is hardly surprising that a dedicated wide-format printer is necessary for this type of output. For a start, the inks are different to conventional UV-curable formulations as they require specific black, red, blue and yellow which provide high gloss print modes essential to provide the reflective and colour box specifications required for this type of production.
Mutoh developed this printer so that the machine, its media, ink and UV protection overlay film all meet the requirements of the European standards for the road traffic and safety sector. Working in conjunction with strategic partner, Nippon Carbide Industries for printing onto Nikkalite retro-reflective sheeting, the end results are signs which have an outdoor durability of up to ten years.
Despite its idiosyncrasies, the Mutoh Zephyr TS behaves like any other UV-curable printer in terms of set-up and operation. Its maximum throughput speed of 45m2/hr on full width printing is more than adequate for this type of application, and production of traffic signs is considerably faster printed digitally than using conventional manual methods.
The Mutoh Zephyr TS uses greyscale drop-on-demand micro piezo technology with XaarJet 760 industrial printheads with 764 active nozzles per head. A dual-shuttered UV-curing lamp system handles bi-directional and high speed printing, with lamps at either side of the shuttle mounted for easy replacement by the operator. The machine also includes Mutoh’s own i2 intelligent interweaving technology to eliminate banding, often noticeable on bi-directional printing, and whose algorithm also minimises ink consumption.
The Zephyr TS comes complete with a workstation and Mutoh’s Grip+, which accepts raster and PDF data. Features include automatic nesting, advanced tiling, pre-flighting and multi-tasking. Able to work with materials up to 1.65m and thicknesses ranging from 0.08 to 20mm, the machine has a choice of three resolutions – 360 x 360, 360 x 720 and 720 x 720dpi. However, the combination of intelligent interweaving and the fact that traffic signs require solid areas of colour means that the lowest of these options is easily sufficient for the majority of applications.
As a certified solution for European road traffic sign standards, the Mutoh Zephyr TS has been purpose-designed to meet all essential criteria in an easy-to-use wide-format turnkey system. The cost is £82,490 and the machine is available from authorised UK distributor, Colourgen.