Innovative, Safe & Sustainable Inks for Flexography

Making a Difference

Two recent ink system introductions are next-generation developments helping brand owners in the flexographic segment achieve their sustainability goals.

Genesis FS flexographic solvent washable inks follow in the footsteps of the highly successful Genesis GS gravure solvent washable inks that meet the PET-CG-02 Critical Guidance Protocol established by the Association of Plastic Recyclers.

“Genesis FS allows printed PET labels to be washed and recycled in the PET recycling process. This produces a cleaner PET plastic,” says Kim Hill, R&D director at INX. “Washable inks release completely from the film with particles large enough to be easily filtered and removed from the wash solution. Due to the unique formulation and pigment selection, there is minimal bleed in the caustic bath solution and a reduced impact on recycled PET discoloration,” she explains.

“The end result is it allows for increased recovery of high-quality, clean and recycled PET resin flakes, and new clear bottles can be made from the circular reuse of recovered materials. This contributes to a circular economy, boosts the worldwide recycling rate, and reduces the volume of plastic bottles in the marine environment.”

The recent introduction of INXhrc RC, a UV dry offset ink for rigid plastic and foam-based containers using clean, renewable and sustainable ingredients, represents the next chapter of INXhrc natural-based inks that first reached the market in 2017. It also illustrates the evolution path INXhrc has taken.

Initially only a water-based flexography product, INXhrc has since expanded to include solvent, oil and energy-cured formulations for flexography, gravure, conventional and dry offset technologies, says Jim Garvey, INX’s technical manager.

“In addition to expanding the breadth of the product line, R&D has dedicated resources to evaluate raw materials and experiment with formulations aimed at increasing bio-renewable content and overall product performance,” he mentions.

“These efforts have generated INXhrc product offerings that can now reach above 90 percent bio-renewable content on some applications. We are constantly evolving the core formulation of INXhrc. The product that started it all remains the same today and continues to be one of the most effective products in the market.”

Results & Efficiencies

Dart Container Corp partnered with INX several years ago. Headquartered in Mason, MI, the world’s largest manufacturer of foam cups and containers has 45 production facilities, distribution centers and offices in eight countries. All use INXhrc inks on various polystyrene foam cups and other disposable food service packaging solutions to help with their sustainability program. It’s a partnership that is working well for both sides.

“The marketplace today is demanding more sustainable products than ever before. By partnering with INX and using renewable ink, we have a sustainable story to tell,” remarks Mike Peloquin, director of manufacturing – print, at Dart Container’s Federalsburg, MD location.

“Our platform is to innovate new products and processes with sustainability in mind, and we are investing in solutions to allow our products to be recovered.” Peloquin indicates that since Dart began using INXhrc in 2017, its plants have significantly reduced VOC emissions. Through November 2022, Dart has replaced over 750,000 pounds of crude petroleum-based solids with natural sustainable products and 953 tons of avoided CO₂ emissions with the replacement of the petroleum-based solids.”

Peloquin added that the Dart team is seeing increased machine performance on press, with less plate washing needed, less scrap waste and higher print efficiencies.
Teamwork & Troubleshooting

“INX works hand-in-hand and side-by-side with our pressmen and press management in the facilities where we have them in the plants. They are part of our continuous improvement and operational excellence efforts and sit in on our Kaizen events. They have been very helpful with improving our overall machine efficiencies,” he reports.

Doug Salisbury, VP, national accounts said both the INX local and national support teams actively participate in the Kaizen events because they are all encompassing and yield valuable information while covering every manufacturing step.

“Our staff keeps data records on specific press usage by SKU and any process variation identified based upon usage changes or ink toning time,” he says. “This information is valuable in identifying the root cause and impact on quality.”

Salisbury points out the INX checklist is widespread, and all contribute to supporting Dart’s sustainability program.

“The team also reviews new print designs and provides recommendations to improve productivity and ink performance by specifying cell and volume specifications,” he states. “Local staff troubleshoots all ink related press issues and if needed, ink formulations are updated for future production requirements. We also actively participate in a process for print quality improvement and performance. This includes recommendations for alternate material chemistries overseeing the press trials and confirming end-use performance for printed article specifications.”

Despite the COVID-19 pandemic and the subsequent interruptions to the supply chain and shortages of qualified labor, INX’s sustainability timetable remains on schedule. In fact, the company was able to complete expansion of its world-renowned R&D facility in West Chicago, not far from its headquarters in Schaumburg, IL.

“We indicated previously our goal to reduce CO₂ emissions and we are making excellent progress,” sums up Renee Schouten VP, marketing. “Through 2022, INXhrc water, solvent and conventional offset inks have replaced 17 million pounds of carbon emissions. That has grown significantly from nearly five million pounds at the end of 2020. Brand owners and printers also benefit since there is no sacrificing of machine, processing and end-of-use product performance.”