Durst Digital Structure - The (r)evolution in the ceramics tile industry

With Digital Structure, Durst continues a revolution in the tile industry started in early 2000. At the beginning of the new millennium, Durst was one of the first manufacturers to adapt digital printing technology to industrial ceramic tile production.

The benefits of the new technology were quickly very apparent to ceramic tile producers, as it enabled for the first time a full edge to edge decoration of textured and flat surfaces, with a clearly visible increase in image quality and decor variety. Durst's high-performance printing technology thus transformed ceramic tiles into a high-quality decorative object that advanced overnight to interior design. Whether natural stone imitations, wood decors or sophisticated & graphical designs, digital printing technology enables high-resolution, realistic designs with impressive three-dimensionality, reproductions with very fine details, flexible print runs and print-on-demand to optimize inventory.

Within a decade, in ceramics digital decoration overtook the classic flexographic printing process and has been established as the new standard. This development also accelerated the internationalization of Durst with more than 1.000 Gamma printing systems installed worldwide.

One of the key advantages of the digital, non-contact printing technology is also the ability to decorate textured tile surfaces. Thanks to the very high resolution with a full dynamic range of 0-100%, it is possible to achieve designs with an extremely naturalistic look, both visually and haptically, such as stone and marble designs, wood grains or graphical matt/glossy effects.

In today's traditional production process, the structure of the tile is created by means of molds in the press limited to very little variation (Ø max. 4-6 different structures depending on tile size), which is subsequently decorated digitally in a non-synchronous manner. The decors must be prepared in such a way that the lack of interaction between structure and decoration is not too noticeable. In addition, the mold in the press must be changed for each different decor (wood, stone, graphic decor, etc.). Due to the necessary setup times, small production runs and frequent changes are economically not feasible.

With the introduction of the revolutionary Durst Gamma DG/RockJET™ digital structure printing technology, Durst has provided an important solution for this problem and enabled for the first time a production process with very high flexibility and degree of automation. This means that now both the structure and the decoration are printed fully digital, thus enabling a very efficient, flexible and production independent from the batch size. Thanks to the unlimited, non-repeating structures in perfect match with the décor, ceramic tiles produced with Gamma DG feature an impressively realistic, natural look providing an immediately visible value added. Crucial for the exact matching and precision between structure and decoration is a perfect and reliable synchronization between the Gamma DG structure printer and the Gamma XD decoration printer.

Durst TRUE DIGITAL PRODUCTION is the evolution in an industry that consistently relies on digitalization and continuously seeks new technological innovations to allow new product ideas and to strengthen its market position.

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