Indirect Benefits
So, if a press can deliver adequate speeds and quality, what are some of the sustainable results derived? A number of companies have introduced significant sustainable features. To help customers explore these, SOMA has worked with its partners to explain how the cooperation between media, ink, software, prepress services and press companies can make a true impact on the environment. Here is a brief summary:
Find a better material: It takes from 500 to 1,000 years for plastic to degrade, while paper bags take only a few months to decompose. As we are well aware, consumers have become increasingly concerned about the environmental impact of packaging. Sustainability is a key business objective for many organizations, and employing packaging with verifiable eco-credentials is seen as a vital part of that strategy.
Governments, brands and, of course, materials suppliers are responding to offer new materials. There are a number of objectives:
- The package should be fully recyclable, or reduce the carbon footprint
- New packaging must not impact current product quality
- The appearance of new packaging must not be compromised, nor should the performance—feel, ease of opening, etc.
- New packaging should be fully useable on current equipment, and the impact (cost/timing) of modifications or new equipment should be known
Sciencedirect.com says that at least 40 percent of the waste we generate globally would be suitable for anaerobic digestion (AD), where microorganisms break down organic materials (and/or composting). Every ton of organic waste diverted from landfill to AD and composting saves the equivalent of 1.5 tons of CO2 emissions, creates 100 liters of biofuel, and creates soil-improving digestate and/or compost.
Matching and extending your colors: While many are impressed with the ability to print more impactful colors, most will tell you that the more significant story of expanded gamut (EG) or fixed palette printing is that of economics, and the resulting environmental impact.
You are mixing colors on press, not in the inkroom. By avoiding the ink changes between runs, a printer can reduce wasted ink, washing detergents, work and time. This results in a more ecological package printing process with more run time, less setup time, less cleaning, less waste and an easier match to a proofing system.
Ink inventories are reduced because there is less need to store expensive spot colors. It also means no anilox change, reduced usage of solvents for washing the press, and the ability to print multiple jobs on the same run.
EG has become a hot topic and a number of companies offer solutions.
Case in point: SOMA collaborated with Flint Group and Marvaco to work on an eco-friendly, full HD, expanded gamut print (EGP) on BOPP film. At the July 2020 SOMA Online Product Launch Webinar, the live printing of two demanding print designs showcased that to print sustainably and in a resource-saving manner is of particular importance.
Marvaco’s GreenerPrinting EGP decreases the use of inks, minimizes the flexographic plate consumption, saves wastage and totally eliminates the ink washes during the job change. Furthermore, gang-run printing allows high flexibility to print short jobs more ecologically and efficiently. With a press that eliminates bouncing, the short repeat length can run stable at high speed without traditional quality issues of bouncing or uneven dot gain. Moreover, the partners’ development work increased the opacity of the white to the highest level while simultaneously decreasing ink consumption.
Choosing the right plate: The right plate can also reduce operating costs and energy. Flint Group is one major manufacturer that offers solvent washable as well as thermal printing plates and processing equipment. For example, the nyloflex XVH thermal printing plate used on the demo job is a flat top dot plate for the flexible packaging market. It is processed with the nyloflex Xpress Thermal Processing System. The benefits of this solution result in up to 88 percent reduction in electricity, compared to some processors, due to infrared pre-heating.
The nyloflex Xpress System leads to a plate processing time of 45 minutes. This sustainable solution reduces operating costs and improves productivity while delivering excellent print quality. The nyloflex FTS is a solvent washable, versatile flexographic plate with inherent flat top dots for multiple segments, inks and substrates. The plate reduces complexity while providing the highest print quality results.
When optimized with the right press, the right choice of plates provides excellent, high-quality printing.
“Sustainability is a key business objective for many organizations, and employing packaging with verifiable eco-credentials is seen as a vital part of that strategy. ”
Make the ink disappear: There are a few sustainable categories that classify both substrate and inks.
- Degradation means the polymeric chain of a material will be cut under certain conditions—for example, UV light—forming small, brittle particles
- Bio-degradation signifies the polymeric chain of a material will be attacked by organisms, resulting in a cut of that chain and a subsequent loss of stability and structure. This happens with wood and cotton
- Composting describes a test program, under which materials must pass
Dry ink films are composed of about 30 percent to 40 percent pigment material. Organic pigments do not biodegrade more than 90 percent. Therefore, organic pigment-based inks do not comply with biodegradation requirements. With biorenewable technology, ink and coating systems are becoming environmentally friendlier.
For example, compostable coatings can produce a 50 percent reduction in CO2. Their certified range of inks can be used for compostable packaging. Flint TerraCode inks, used in printing the sample work, are available with exceptional levels of bio-renewable content—100 percent of the resin system made from renewable resources—suitable for applications that require higher resistance properties; and with biomass balance technology that offers the same performance as acrylic systems.
Working with UV LED inks: One of the primary reasons UV LED has become a popular choice is that it has a number of sustainable benefits. UV LED uses significantly less power than other drying systems, because LED lamps need less energy—on average, as much as 50 percent less, reducing an energy bill. It is a VOC emission-free process, with no ozone extraction required, resulting in reduced infrastructure exhaust systems, air exchange and power delivery.
There are no solvents, which means no dangerous fumes, no incinerator or solvent recovery and, thus, no risk of explosion—and with it, lower insurance premiums for fire risk and disposal costs for waste ink. Operators using these technologies report they better the work environment. Presses are cleaner and maintenance easier.
Saving on power, combined with elimination of spray power, attributable to the ability to print alcohol free with VOC-free inks, makes a strong positive environmental impact.
Manage color to reduce ink: You need a good press to ensure accurate—and consistent—dot reproduction. Once that is assured, color management becomes easier. The ability to target color combinations can save press time. Using a capable press with good color management can save a considerable amount of ink. A good color management system will allow printers to reduce makereadies as much as 25 percent, increase capacity, save ink and reduce waste.
As you can see, many companies are developing advanced systems that, in their own way, help to preserve the environment. Collectively, a print provider can significantly impact what comes out of the press.
What does the right press have to do with these materials? You need a press and plate system that will hold the ink and make an exceptional impression on the substrate, without bounce or any other degradation of quality. That, and the reduction of energy use and makeready waste, are a great start. Partnerships with other companies can significantly increase sustainability.
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