The Next Competitive Focus in Digital Inkjet: From High-Speed Printing to Full Closed-Loop Intelligent Control
2026 All in Print Shanghai observation: missing-nozzle detection, automatic compensation, inline spectrophotometric color measurement, and printhead life management
One example is the Canon varioPRINT iX: it can detect missing nozzles and apply automatic compensation. The goal is to reduce white lines and manual intervention.
What is the real competitive advantage of an industrial digital press?
Is it 1200 dpi? Is it 100 m/min or 150 m/min? Is it how many printheads are installed?
These parameters matter.
But for printing companies in continuous production, there are more practical questions:
If a printhead suddenly drops out, can the machine detect it itself?
If white lines appear, can it compensate automatically without stopping?
If a batch of paper or film is changed, can the machine measure color and calibrate itself?
If printhead condition gradually deteriorates, can the system warn early instead of waiting until scrapping?
These questions are determining the next stage of competitiveness for industrial digital inkjet equipment.
From October 12 to 16, 2026, the 10th All in Print China was held in Shanghai. The theme was 'Digital Intelligence Printing the Future.' Heidelberg, Kodak, HP, Canon, Epson, Konica Minolta, Durst, SCREEN, and other international and domestic manufacturers participated.
We are looking not only at how much equipment speed has increased, but also at representative technologies from several international vendors to observe deeper changes taking place in industrial inkjet.
1. The First Shift: Nozzle Dropout Should No Longer Depend on Operator Detection
For industrial inkjet equipment, missing nozzles are a long-term problem.
Nozzle clogging, micro bubbles in ink, jet direction deviation, and drop volume changes can all cause print streaks, density unevenness, and localized missing color.
Traditional equipment usually follows this process:
Find white line -> stop -> print nozzle test chart -> manual inspection -> clean printhead -> reprint.
The problem is that by the time an operator finds the defect, a large amount of waste has often already been produced.
On high-speed single-pass equipment, this loss is even more obvious.
Take a machine running at 100 m/min. Even if a fault is discovered only 30 seconds late, it has already output 50 meters of material.
Therefore, the first problem future equipment must solve is to make printhead faults move from manual discovery to automatic identification.
Case 1: Canon varioPRINT iX - Missing-Nozzle Detection and Automatic Compensation
Canon's varioPRINT iX series provides a very representative solution.
Its nozzle quality control includes two core functions:
NAC (Nozzle Activity Control)
The equipment periodically prints a dedicated test chart, and a built-in scanning system identifies non-working nozzles.
Once an abnormality is found, the system can temporarily mask the faulty nozzle and use adjacent nozzles of the same color to compensate, minimizing white lines.
NUC (Nozzle Uniformity Control)
By scanning test charts at different gray levels, it determines whether each nozzle output is uniform and automatically adjusts it to reduce streaks and density unevenness.
According to Canon public technical documents, NAC and NUC can both be executed at set intervals during production.
This means the equipment is no longer only passively executing printing tasks. It can detect its own output and feed back adjustments.
More notably, when compensation is not enough to maintain quality, the system can also perform printhead maintenance.
Detection, compensation, and maintenance begin to form a complete control chain.
2. The Second Shift: Direct Inspection of Normal Printed Images Without Test Charts
Case 2: Durst Hawk AI - From Defect Detection to Real-Time Correction
If Canon shows mature periodic inspection and automatic compensation, Durst's Hawk AI represents another development direction.
Durst publicly describes that Hawk AI uses a camera vision system to analyze printed images at normal production speed, identify printing abnormalities including missing nozzles, and perform inline correction.
One prominent feature is:
It does not need to print a special test chart for detection, and it does not require operator intervention every time.
This is important for labels, packaging, and continuous web printing.
Traditional test chart inspection has a problem: it only reflects nozzle status at the moment of testing.
In actual production, nozzle faults can appear at any time.
If the system can directly analyze normal printed images, it has a chance to shorten the time from fault occurrence to correction.
However, it should be noted that so-called 'real-time compensation' mainly corrects subsequent output. It does not mean that erroneous ink drops already printed on paper can be directly repaired.
For high-speed equipment, the real difficulties of vision inspection include:
- How to distinguish design images from actual print defects;
- How to accurately locate a defect to a specific printhead and nozzle;
- How to control the latency of image analysis and compensation feedback;
- How to avoid incorrect compensation introducing new color differences or streaks.
An important direction for future industrial inkjet is not only to see defects, but to understand them and automatically take the correct action.
3. The Third Shift: Inline Spectrophotometric Color Measurement Brings Color Management Inside the Equipment
Normal nozzles do not guarantee that printed color is correct.
In industrial production, paper, film, ink, temperature, and equipment condition all affect the final color.
Traditional color management usually relies on external instruments, such as the X-Rite i1Pro series:
Print color chart -> manual sampling -> spectrophotometric measurement -> build ICC -> adjust RIP -> print again for verification.
This method is effective, but it requires high operator expertise and involves a longer process.
Now, some vendors have integrated spectrophotometric color measurement systems directly into printing equipment.
Case 3: Epson SurePress L-4733AW + AS-4000
The Epson SurePress L-4733AW digital label press can be optionally equipped with the SureSpectro AS-4000 inline spectrophotometric color measurement module.
This is a color management solution worth studying in depth.
The AS-4000 can complete color patch measurement inside the equipment and, with software, achieve:
1. Automatic ICC Profile creation
For different papers or films, it prints a standard color chart, automatically measures it, and generates the corresponding color profile.
2. Color consistency calibration across multiple devices
It reduces output differences between different devices.
3. Print color accuracy verification
It measures printed color patches and determines whether actual output meets target requirements.
4. Spot color matching
Combined with color management software, it improves the efficiency of brand spot color matching.
The AS-4000 uses Epson MEMS spectral measurement technology, not an ordinary RGB camera.
It should be noted that this system achieves automatic color measurement and calibration by positioning and measuring color charts. It does not continuously measure every printed pixel at the highest printing speed.
But it already indicates an important trend:
Spectrophotometers are moving from external auxiliary tools to becoming components of digital printing equipment.
In the future, equipment will not only need to know whether it has ejected ink drops, but also whether the ejected color is correct.
4. The Fourth Shift: Extending from Print Quality Inspection to Automatic Printhead Maintenance
Case 4: Different Technical Routes from Canon, SCREEN, and Epson
One of the largest long-term costs of industrial inkjet equipment is printhead maintenance and replacement.
In particular, different industrial printhead platforms such as Kyocera, Ricoh, and Epson have their own technical requirements for use environment, ink adaptability, cleaning methods, and maintenance cost.
In the past, maintenance was usually scheduled cleaning, or cleaning after defects appeared.
But this approach has two problems.
On one hand, delayed cleaning allows print defects to continue expanding.
On the other hand, excessive cleaning also consumes ink, increases waste ink, shortens effective production time, and may increase the burden on printheads and maintenance mechanisms.
A more reasonable future approach is to perform maintenance based on actual printhead condition.
Canon: After detection, decide whether to compensate or clean
Nozzle detection is used to judge the degree of abnormality. If compensation is possible, compensate first. When too many failed nozzles affect quality, perform maintenance.
SCREEN: Combine print inspection with maintenance decisions
SCREEN's JetInspection and other solutions reflect the direction of full-width print inspection, quality management, and anomaly tracking. Specific automatic maintenance and compensation capabilities need to be confirmed according to equipment model and optional system.
Epson: Using piezoelectric technology to study nozzle self-detection
Epson's NVT nozzle verification technology can judge ejection status through the residual vibration characteristics of piezoelectric elements.
This differs from external CCD inspection: it attempts to identify abnormalities from the physical response inside the printhead.
It should be noted that some Epson devices have NVT, but this does not mean that all i3200 OEM printheads have opened the same detection interface to third-party control boards.
These technical routes are not exactly the same, but the final goal is consistent:
Identify problems as early as possible in printhead performance deterioration and restore normal production with the minimum maintenance cost.
5. Printhead Life Will Become an Important Competitive Indicator for Future Industrial Equipment
For high-speed industrial inkjet equipment, the printhead is not only a printing component, but also a production asset that requires continuous investment.
We believe future equipment vendors will increasingly value the following capabilities:
First, printhead health assessment.
It should not only record whether there are missing nozzles, but also track the number of weak nozzles, anomaly frequency, recovery conditions, ejection stability, and maintenance history.
Second, condition-based maintenance, not simple scheduled maintenance.
Based on inspection results, decide whether wiping, priming, flushing, or other maintenance procedures are needed.
Third, coordination between automatic compensation and maintenance.
Minor abnormalities can first be handled by nozzle replacement to maintain production. When abnormalities continue to expand, schedule cleaning. After maintenance, automatically retest to confirm recovery.
Fourth, printhead life prediction.
Combine nozzle fault trends, ejection counts, operating temperature, maintenance frequency, and historical records to evaluate changes in printhead performance.
It must be emphasized here: there is currently insufficient evidence to prove that these functions can directly extend the physical life of printheads on all devices.
However, reasonable detection, compensation, and maintenance strategies may reduce unnecessary cleaning, lower abnormal production losses, and extend the effective service period during which printheads maintain acceptable print quality.
This is the value industrial users truly care about.
6. What Kind of Full Closed-Loop Control System Will the Next Generation of Industrial Inkjet Machines Have?
We believe future industrial digital inkjet equipment will gradually build four interconnected closed loops.
Layer 1: Nozzle Health Closed Loop
Nozzle condition detection -> fault localization -> automatic compensation -> cleaning when necessary -> retest verification.
Layer 2: Print Quality Closed Loop
CCD/CIS inline scanning -> streak, registration, density, and defect analysis -> automatic adjustment -> re-inspection.
Layer 3: Color Management Closed Loop
Inline spectrophotometric measurement -> Lab and Delta E calculation -> calibration curve or ICC update -> print verification.
Layer 4: Production Management Closed Loop
Order data -> printing -> visual inspection -> quality traceability -> automatic reject or reprint -> production records.
When these four loops are connected, printing equipment is no longer just an output machine that accepts commands.
It will gradually become an intelligent system that can sense, judge, correct, and maintain its own production state.
This will also change the value structure of industrial inkjet equipment.
In the past, customers buying equipment mainly compared speed, precision, printhead brand, and equipment price.
In the future, customers may focus more on:
- How many hours of stable production per day;
- What the actual qualified product rate is;
- How quickly production can recover after a missing nozzle;
- Ink and maintenance cost per square meter;
- How long printheads can maintain acceptable print quality;
- Whether the equipment can reduce dependence on skilled operators.
The real efficiency of equipment is not the nominal maximum speed, but the ability to stably output qualified products over the long term.
7. Where Are the Next Opportunities for Domestic Industrial Inkjet Equipment?
In recent years, domestic industrial inkjet equipment has developed rapidly.
From Epson i3200 custom equipment to high-speed single-pass equipment using industrial printheads such as Kyocera and Ricoh, Chinese manufacturers have formed relatively complete manufacturing and supply chain capabilities.
But the next stage of competition cannot stop at adding more printheads, increasing mechanical speed, and lowering equipment price.
We believe three directions deserve focused investment.
First, detection and compensation technology across printhead platforms.
Build a CCD inspection, nozzle mapping, defect identification, and compensation software platform that can adapt to different printheads, reducing dependence on a single printhead brand.
Second, low-cost inline spectrophotometric color measurement and automatic calibration.
Learn from solutions such as Epson AS-4000, enabling industrial equipment to automatically measure color, build calibration curves, and verify output based on actual materials.
Third, printhead health management and predictive maintenance.
Connect nozzle status, cleaning records, operating parameters, and print quality data, shifting from fault repair to condition management.
These capabilities can be developed independently by complete machine manufacturers, and they also have the opportunity to form independent industrial control modules serving different equipment manufacturers.
For equipment manufacturers and overseas distributors, these functions also have a practical value: reducing on-site service visits, shortening fault handling time, and lowering after-sales service cost.
8. Looking at the Technology Direction for the Next Three to Five Years from 2026 All in Print China
Through observing representative technologies from international vendors, we believe industrial digital inkjet is undergoing three changes:
From 'high speed' to 'effective capacity.'
The maximum speed of a machine is still important, but stability, waste rate, and maintenance downtime will increasingly affect purchasing decisions.
From 'manual calibration' to 'automatic closed loop.'
Nozzle detection, print quality control, inline spectrophotometric color measurement, and automatic maintenance will gradually integrate instead of remaining independent functions.
From 'selling equipment' to 'selling continuous production capability.'
The future competitiveness of equipment vendors lies not only in mechanics and printheads, but also in software, sensors, data analysis, remote service, and full lifecycle management.
Of course, a true full closed loop does not mean all actions can be completed instantly, nor does it mean every device must be equipped with expensive sensors.
Different speeds, widths, and application scenarios require different technology combinations.
But the direction is becoming increasingly clear.
Conclusion: The Printing Press of the Future Should Be Able to Find and Correct Problems on Its Own
From Canon's automatic missing-nozzle compensation to Durst's visual real-time correction; from Epson's inline spectrophotometric color measurement to SCREEN's print quality inspection system, international vendors are advancing the automation of industrial digital inkjet from different directions.
We believe the most valuable upgrade for future industrial inkjet equipment is not necessarily another 20% increase in nominal speed.
Instead, it is to enable equipment, during long production runs, to detect abnormalities earlier, complete corrections faster, control color more accurately, and maintain stable production at lower maintenance cost.
From nozzle to image, from color to maintenance, from detection to automatic control - full closed-loop intelligent inkjet is becoming the next stage of industrial digital printing.
This is also the technical direction we followed at 2026 All in Print Shanghai and hope to discuss with equipment manufacturers, printhead suppliers, control system developers, and printing companies.
Technical Exchange and Collaboration
We have long been engaged in technical service, control system research, and industrial equipment repair for prepress and digital printing equipment. We continue to focus on industrial inkjet, CCD inline inspection, automatic nozzle compensation, color management, and printhead health management.
We welcome industrial inkjet complete machine manufacturers, printhead control board developers, and vision inspection and color management companies to exchange and collaborate, jointly exploring low-cost, high-reliability intelligent closed-loop solutions suitable for domestic equipment.
DTP TECH | Industrial Printing Equipment Technical Exchange
Website: www.allctp.com
References: Canon varioPRINT iX official technical manual; Durst Hawk AI official technical introduction; Epson SurePress L-4733AW and SureSpectro AS-4000 official materials; SCREEN official product materials; 2026 All in Print China official information.
Note: This article uses the 2026 All in Print China as an observation background. Some cases are representative existing technologies of exhibiting brands and do not mean that the specific models or functions were all demonstrated on-site at this exhibition.
If you are working on industrial inkjet presses, printhead control boards, vision inspection, or color management systems, what would you most like to see next in closed-loop control?