Continuous Inkjet (CIJ) technology was originally developed to meet a simple but critical need—high-speed, non-contact coding across a wide range of substrates. While it successfully addressed these requirements and became an industry standard, the underlying technology has evolved relatively little over the decades. In contrast, the operational environment, workforce dynamics, and cost pressures faced by manufacturers have changed significantly.

Today, companies are encountering a growing disconnect between legacy CIJ systems and modern production expectations. The reliance on highly skilled technicians and experienced operators—historically necessary to maintain uptime and print quality—is becoming a major liability. Labor shortages, increasing wage demands, and high turnover rates are driving up the true cost of maintaining these systems, while institutional knowledge continues to decline as seasoned personnel retire.

At the same time, environmental and safety considerations are becoming more prominent. Traditional CIJ systems generate solvent waste that requires specialized hazardous disposal, with costs rising year over year. Additionally, operator concerns around prolonged exposure to solvents are increasing, placing further pressure on organizations to reassess coding strategies.

Some manufacturers have explored alternatives such as laser coding. While lasers eliminate consumables, they introduce their own set of challenges, including high upfront capital investment, safety risks, and limitations in substrate compatibility—preventing them from being a universal replacement for CIJ.

Compounding these issues, many CIJ manufacturers have historically prioritized low initial purchase price over long-term performance. This has led to widespread adoption of systems that may appear cost-effective upfront but carry significant hidden costs over their operational life—particularly in maintenance, downtime, consumables, and waste management.

This presentation will highlight the often-overlooked total cost of ownership associated with traditional CIJ technology, with a focus on:

The financial impact of unscheduled downtime and ongoing maintenance
Rising labor and training costs tied to system complexity
Hidden environmental and hazardous waste disposal expenses
The gap between initial purchase price and true lifecycle cost

The objective is to provide PMMI members with a clearer understanding of these hidden cost drivers and to challenge conventional thinking around CIJ procurement and operation—shifting the conversation from upfront cost to long-term value and sustainability.

PACK EXPO International 2026

Hidden Costs of Traditional CIJ Printing

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