Print Quality Assessment of QR Code Elements Achieved by the Digital Thermal Transfer Process

TL;DR

This paper studies how different UV varnish thicknesses affect the print quality of QR codes using a digital thermal transfer process.

Contribution

The study introduces a method to assess QR code print quality using varying UV varnish thicknesses in a hybrid printing process.

Findings

Smallest QR code elements show uneven imprint quality with thin UV varnish.

Increasing UV varnish thickness improves the stability and evenness of printed QR codes.

The highest technical precision was achieved with a 21 µm UV varnish thickness.

Abstract

The new European Regulation (EU) 2025/40 includes provisions on modern packaging and packaging waste. It defines the use of image QR codes on packaging (items 71 and 161) and in personal documents, making line barcodes a thing of the past. The definition of a QR code is precisely specified in ISO/IEC 18004:2024. However, their implementation in printing systems is not specified and remains an important factor for their future application. Digital foil printing is a completely new hybrid printing process for applying information to highly precise applications such as QR codes, security printing, and packaging printing. The technique is characterized by a combination of two printing techniques: drop-on-demand UV inkjet followed by thermal transfer of black foil. Using a matte-coated printing substrate (Garda Matt, 300 g/m2), Konica Minolta KM1024 LHE Inkjet head settings, and a transfer temperature of 100 °C, the size of the square printing elements in QR codes plays a decisive role in the quality of the decoded information. The aim of this work is to investigate the possibility of realizing the basic elements of the QR code image (the profile of square elements and the success of realizing a precisely defined surface) with a variation in the thickness of the UV varnish coating (7, 14 and 21 µm), realized using the MGI JETvarnish 3DS digital machine. The most commonly used rectangular elements with a surface area of 0.01 cm2 were tested: 0.06 cm2, 0.25 cm2, 1 cm2, 4 cm2, and 16 cm2. The results showed that the imprint quality is uneven for the smallest elements (square elements with base lengths of 0.1 cm and 0.25 cm). The effect is especially visible with a minimum UV varnish application of 7 μm (1 drop). By increasing the amount of UV varnish and the application thickness to 14 μm (2 drops) and 21 μm (3 drops), respectively, a significantly more stable, even reproduction of the achromatic image is achieved. The highest technical precision was achieved with a UV varnish thickness of 21 μm.

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