by Cassandra Balentine
Toner advancements continue to expand this mature technology’s appeal in modern production print environments. It is particularly well suited for short- to medium-length runs where high quality is of utmost importance. The application range for toner-based print production is enhanced with advanced inline finishing options as well as fifth and sixth stations that enable specialty colors, finishes, and effects.
“Two shining examples where toner production presses excel include the diverse range of supported media and distinct inline finishing, shares Robert Barbera, director, Production Printing Solutions Strategy, Canon U.S.A., Inc.
Above: Print samples with embellishment created on a Xeikon dry toner device.
It’s important to note that it isn’t toner versus inkjet versus analog, but instead a combination of technologies offer print providers versatility and competitiveness.
“It is not unusual to see toner systems sitting side-by-side with inkjet presses, as well as other printing technologies, and these can complement each other for different production demands and economic decisions,” comments Andrew Vecci, director, portfolio and product Management, Ricoh USA, Inc.
Where Toner Excels
Media versatility, print quality, and configuration options are advantages toner-based production print systems offer modern print shops.
Toner-based printers are known for delivering quick, print on demand capabilities and short turnaround times through speed and efficiency. “These printers tend to have lower upfront investments and operational costs, especially when it comes to maintenance and the cost of consumables, compared to alternatives like inkjet technology. This is key in environments where time and cost are critical,” adds Paul Albano, senior manager, product marketing, Toner Press Solutions, FUJIFILM North America Corporation.
Unlike inkjet, Matthew Raab, director of global portfolio marketing, Xerox Corporation, points out that toner provides immediate dry time, making it ideal for on demand, high-quality applications such as direct mail, catalogs, and variable data printing.
One area where toner-based production presses continue to advance involves media flexibility and versatility. “The ability to leverage a variety of substrates, weights, and specialty stocks translates to expanded customer application possibilities,” says Vecci.
In addition to typical coated and uncoated medias, Barbera says digital presses print successfully on heavier weight and thicker substrates as well as numerous specialty medias, including synthetic, envelopes, textured, and even magnetic media.
Further, support of longer sized sheets helps print service providers (PSPs) expand versatility with new and innovative high-value applications.
Toner systems are also known for exceptional print quality, achieving output with visual clarity, fine lines, crisp text, and realistic image reproduction. “With the addition of fifth station colors, PSPs can expand gamut but also produce high-value applications through the use of embellishments and effects with gold, silver, neon pink, neon yellow, clear, white, and invisible red,” shares Vecci.
Raab agrees, noting that six-color and specialty color printing capabilities expand toner’s creative possibilities, allowing for metallics (silver and gold), fluorescents, white, and clear toners to be integrated into a single production run, elevating print applications beyond traditional CMYK.
The introduction of white toner can significantly expand and diversify application offerings. “With white toner, they can now print on a variety of colored media—including transparent and metallic substrates—by using it as the first layer. This approach allows the press to achieve a full-color gamut, utilizing the white toner as a base layer for the CMYK toner. And impressively, all toner is applied in a single pass,” shares Jason Dizzine, VP, portfolio management and planning, Konica Minolta.
Software collaborations also play a role. For example, Sharp’s six-color production presses are integrated with Color-Logic software to offer added colors and embellishment like fluorescent, metallic finishes, and white ink on black paper to captivate customers and create tactile, high-impact prints.
Dimitri Van Gaever, global marketing director, Xeikon, agrees that toner technology’s ability to enhance color accuracy and vibrancy is one of its strengths. “With the use of additional colors, dry toner presses can expand the color gamut, ensuring precise brand color matching and meeting the strictest design requirements. This makes them ideal for industries where consistency and detail matter, such as luxury packaging, high-end marketing materials, and personalized print runs. Furthermore, dry toner technology is highly compatible with a range of finishing and embellishment processes, including foiling, embossing, and lamination, adding value to the final printed product.”
The configuration options available in toner-based production print lineups are also attractive to many PSPs.
Production toner presses offer support of inline finishing solutions. “These modules can help provide increased efficiency and reduce the additional labor costs and time associated with offline finishing, as well as support customers in their efforts to shorten turnaround times,” says Barbera.
For smaller PSPs and in-plants with lower print volumes and limited real estate, Vecci points out that toner-based systems are accessible and available in a range of configurations.
Food safety and sustainability considerations also come into play.
Van Gaever says that a unique advantage of Xeikon dry toner printing is its food-safe approval, making it suitable for applications that require direct or indirect food contact. “Unlike some other print technologies, dry toner formulations meet stringent regulatory standards, allowing them to be used for food packaging, labels, and even customized short-run packaging solutions for e.g. paper-based mono layer construction food packaging. This added benefit further enhances its appeal for brands looking for safe, high-quality, and visually striking print solutions on the shelves,” he explains.
Top Trends
Increased automation, personalization, improved sustainability, and additional color capabilities are top toner trends.
Customers should expect to see continual advancements designed to help drive higher levels of productivity. Technologies that focus on keeping a press running include reliability, repeatability, and automation innovations that are becoming more critical as environments struggle to identify trained operators, notes Barbera.
“Increased automation is gaining momentum, both in terms of reducing manual tasks and integrating toner-based production printing with automated workflows. Additionally, artificial intelligence and machine learning to enhance quality, improve efficiency, and reduce human error, are on the rise,” shares Albano.
Demand for more personalization and variable data printing continues. “Toner-based solutions are highly effective for these types of printing applications, making them ideal for commercial print shops and use in direct mail marketing campaigns,” offers Albano.
Print servers such as PRISMAsync help to automate many routine operator level tasks and new cloud-driven ‘press tools’ provide valuable data insight to help operations manage and track their print output. “Canon’s Smart Print Room leverages these various advancements to help customers drive increased levels of productivity and insight into their printer utilization,” says Barbera.
Albano adds that demand for sustainable solutions sparks trends towards eco-friendly toner formulations, lower energy consumption, and reduced waste in production environments.
The adoption of fifth or sixth color stations is growing, enabling PSPs to offer customers more possibilities. “Specialty colors add impact and appeal to print, create premium effects, and accentuate designs,” offers Vecci.
Van Gaever points out that when it comes to dry toner production printing, the future is shaped by technological advancements with hundreds of patents and increasing sustainability considerations. “Key trends we see are higher speeds and productivity complemented with intelligent automation; implementation of dry toner printing in hybrid workflows and complementary deployment in offset and inkjet environments; continued expansion of substrates for a wider range of end-use applications; further development of sustainability initiatives driving legislation for reduced environmental impact; and continued development of extended color capabilities and special effects.”
Added Colors, Embellishment
Print providers are always looking for ways to expand their application range and offer high-value print services. “We are finding near-line embellishment solutions provide customers with a higher level of flexibility and options to help them enhance and expand their range of print applications,” says Barbera.
Kent J. Villarreal, senior product manager, Production Print, Sharp Electronics Corporation, feels that as the production toner market continues to evolve, one of the most significant trends on the horizon is the expansion of inline and near-line embellishments. “The four-color printing market has become increasingly commoditized, making differentiation more critical than ever. To stay competitive, print providers are seeking ways to add value beyond standard CMYK printing.”
The addition of specialty colors and fifth and sixth print stations are a game changer, allowing printers to differentiate their offerings. “Printers are leveraging these enhancements to offer unique, premium-quality prints that command higher margins,” says Raab.
“This introduces new toners such as pink, white, clear, as well as metallics like gold and silver—allowing for more versatile and creative applications, with the ability to add highlights, create textures, or print on dark-colored or transparent materials,” agrees Albano.
This expanded capability opens up new markets for packaging, label printing, and more advanced, luxurious looking marketing collateral, and is “boosting adoption among print shops that want to differentiate themselves with unique products,” comments Albano.
“These solutions enhance the value of toner presses, allowing PSPs to offer more higher value applications, create more differentiation in the market, and increase their profitability,” agrees Vecci.
The integration of specialty colors and additional channels is driving new growth opportunities, enabling PSPs to produce striking, high-margin applications. “These advancements not only enhance the visual appeal of printed materials but also help businesses stand out in a crowded marketplace,” adds Villarreal.
Vecci points out that additional color stations also open up more substrate possibilities. “With white toner as an underlay, it becomes possible to print vibrant images and text on dark and colored papers or to create dramatic effects with high-end appeal. “Embellishments become easy with metallic toners such as gold and silver, and one can even create different shades of metallic such as rose gold and silver blue. And clear toner allows spot varnish effects, adding further value to prints.”
Even though dry toner is a mature technology, Van Gaever says that with expanded color capabilities and unique embellishment options, dry toner printing continues to bridge the gap between traditional and digital printing. “It provides high-value, short-to-medium-run print solutions that stand out. We believe dry toner offers a wide range of end-use applications covering the needs of brand owners and PSPs. Thanks to extra colors like green, blue, and red the already wide gamut can be expanded, but also white and fluorescent offer unlimited creativity and technical combinations. And finally specialty toners like clear, metallic, and security in combination with variable printing of digital provide access to applications that are out of scope for traditional technologies.”
Tried and True
Toner-based production is a mature technology that continues to expand its appeal with options for white, metallic, fluorescent, and clear toners that enable premium, high-value print products.
“As the industry continues to push boundaries, we anticipate further innovation in toner-based embellishments, offering printers greater flexibility and profitability,” notes Villarreal.
Find a webinar on the topic of production toner advancements online at dpsmagazine.com/webinars.
May2025, DPS Magazine
