Printweek – Star product: Kornit Apollo

What does it do?

It’s a high-throughput, totally automated digital direct-to-garment printing system that may output as much as 400 impressions per hour, cured and able to despatch. Every is usually a one-off, or a part of a long term. It’s meant for quantity manufacturing of shirts or hoodies (with or with out pockets) and variations, the place every picture could be distinctive and it could possibly immediately change from dealing with white to colored supplies.

It is a large system, with a 14.8×5.6m footprint, but just one operator is required. All operating prices, together with the machine, set up and consumables, are coated by a single click on charge primarily based on a yearly estimate of gross sales.

When was it launched and what markets is it geared toward?

Kornit has been creating DTG printers because it was based in Israel in 2004, and it developed the primary digital white inks for darkish textiles. Apollo is its largest and quickest mannequin up to now, in a position to deal with volumes as much as one million clothes per yr. It was launched in ITMA 2023 in Milan, Italy, and output clothes have been featured on Kornit’s stand at Drupa – guests have been additionally invited to see one of many massive traces in motion at Kornit’s European HQ in a close-by manufacturing unit unit in Düsseldorf.

In line with Moran Levy, director of Kornit’s Mass Manufacturing Phase: “That is an industrial answer, meant to enhance a fleet of analogue carousels.” The Apollo’s pace is about the identical as a mean carousel, and the idea is that in a high-throughput surroundings, Apollo can maintain one-offs and runs of up to some thousand, alongside standard display print carousels that may deal with the lengthy runs of hundreds of similar clothes.

“Apollo can match a variety of markets, from retail by means of promotional and licensing, because of the flexibility to match Pantone and spot colors, with on-demand manufacturing,” says Levy.

The pace means it could possibly exchange a number of “legacy” DTG digital or analogue printers.

How does it work?

That is an inkjet printing system that may print six colors (CMYK, purple and inexperienced), plus white as a base layer on darkish materials, an ‘intensifier’ and a fixer. The inkjet system is Kornit’s MAX know-how, beforehand used on its high-volume Atlas MAX and Atlas Poly printers, that are slower and have much less automation.

It makes use of Kornit’s Eco Speedy, NeoPigment water-based inks. Kornit says all its inks are designed to satisfy the best environmental requirements in addition to consumption reductions. Eco Speedy ink is licensed to stricter rules and is compliant with GOTS and OEKO Passport licensed, and BlueSign System Associate.

The ink is suited to a variety of material sorts, however is optimised for cotton and cotton- wealthy blends. Kornit cites appropriate materials as cotton, polyester, cotton-polyester blends, Lycra/Spandex, rayon/viscose, silk, leather-based, denim, linen, wool, “and extra.” No offline pre-treatment is required – all of Kornit’s options use its ‘wet-on-wet’ know-how with all processes dealt with internally.

The ‘good manufacturing’ sequence is completely computerized and all of the operator wants do is manually load every garment in the beginning. A clean garment is scanned for dimension and different “related particulars”. Primarily based on this, the pallet will change its dimension mechanically. The operator picks up the clean and arms it on to the semi-automatic loader, which stretches it onto the formed pallet that retains it flat all through printing. There are two printing stations. Pre-treatment is utilized, with the quantity of fixation fluid customised for the particular garment, and the white layer is printed if wanted for darkest clothes. Then the color print is utilized within the second station. Every shirt travels by means of each printing stations, so productiveness is similar for white and darkish shirts.

The automated unloader removes the shirt from the pallet and locations it on one lane of the dryer’s conveyor belt. Sensible curing will regulate in line with garment and remedy in a two-step course of. The inline dryer makes use of know-how developed by Tesoma, an organization Kornit acquired some years in the past, with a hybrid curing system that mixes IR and sizzling air (from a gasoline heater), mentioned to make use of 50% much less vitality than standard dryers.

Lastly the finished garment is transported by belt to a supply bin on the finish, the place it may be picked out for folding and packing.

The embedded front-end is Kornit’s personal Ok-Rip, which takes PDF information and mechanically identifies the required workflow. Levy says this allows mass customisation, providing “unparalleled color accuracy to satisfy the wants of manufacturers and retailers”.

Does it exchange something?

No, Apollo is an all-new system within the Kornit vary, with extra pace and automation. Kornit claims it’s distinctive out there.

What’s the USP?

In line with Kornit, it’s a mixture of “ground-breaking productiveness” with a single operator, because of semi-automatic loading, totally computerized printing with switch to Tesoma-based good curing and supply. It incorporates Qualiset tech for color know-how, and it could possibly reproduce Pantone values and different model colors.

How simple is it to make use of/study?

Levy says: “Apollo makes the coaching brief and simple, since our good manufacturing takes care of all the technical knowhow that’s wanted to function the system. The operator can concentrate on loading and nothing extra, making the coaching course of and ramp-up very fast. We provide full coaching packages that deliver your group up to the mark with all the technical instruments which can be wanted to run the system every day. The method takes two to 4 weeks, and contains all operation, functions and upkeep.”

What does it value?

At Kornit’s Drupa press convention, CEO Ronen Samuel mentioned: “Apollo would value $1.8m (£1.4m), plus ink and repair contract. However as an alternative we provide all-SaaS fashions for clicks, which incorporates the machine. This frees up capital, so shoppers solely pay for clicks, ie bought jobs.”

Whereas Kornit isn’t saying what the cost-per-garment will probably be, this does appear a lovely approach to get into the DTG market with out main outlay. In all probability many one-off orders will come from web-to-print, with fee acquired prematurely.

Are there any installations?

Gross sales and installations have began, with the primary two going to Mad Engine International and T-Shirt Central within the US. There was one sale within the UK to an undisclosed website.

SPECIFICATIONS

Course of Inkjet with Dimatix StarFire 1024 Twinflex printheads, plus inline curing

Colors CMYK plus purple, inexperienced, white and primers

Ink Water-based Kornit Eco Speedy NeoPigment

Max decision 1,200dpi

Garment sorts Shirts and hoodies (with or with out pockets)

Material sorts Cotton, polyester, cotton-polyester blends, Lycra/Spandex, rayon/viscose, silk, leather-based, denim, linen, wool

Max print space 508x508mm with dimension shifting for bigger clothes

Throughput As much as 400 typical shirts/hour

Footprint 5.6×14.8m

Value All coated by click on charge decided by predicted volumes

Contact Kornit www.kornit.com [email protected]

ALTERNATIVES

Kornit claims that the pace and all-in-one automation of the Apollo is exclusive out there, and we haven’t discovered the rest that’s a direct competitor. Different high-volume options embody Brother’s POD providing, however this contains a battery of separate small GTX Professional B garment printers with separate pre-treatment stations, grouped subsequent to a number of lane configurations of the standalone Firefly curing techniques. This enables throughput of as much as 380 shirts per hour with 9 printers and a three-lane Firefly, however it wants three operators with guide loading and unloading of every printer and switch to the Firefly lanes.

Contact Brother garmentprinter.world.brother/en-emea

USER REVIEW

“Apollo is proving significantly precious for each retail and display printing segments, to shorten lead occasions and enhance margins for short-to-medium run manufacturing. Retailers can react in real-time to new consumptions and traits and in addition dramatically streamline stock necessities and prices. Display screen printers can shorten lead occasions to days and even hours” Mad Engine International, San Diego, California