Flexible packaging has experienced tremendous growth over the past few decades due to its versatility, durability, and cost-effectiveness. As the demand for flexible packaging grows, the printing technology associated with it has also evolved significantly. Among the various printing methods, flexographic printing has emerged as a dominant player, thanks in part to innovations in solvent-based flexographic inks. These inks have not only transformed the industry but also present an eco-friendly and economically viable alternative to conventional gravure inks.
Advantages of CI flexo over gravure inks
One of the key reasons solvent-based flexographic inks are gaining traction is their inherent advantages over traditional inks. Central Impression (CI) flexo printing offers a range of benefits that cater to modern-day packaging requirements:
Toluene-free and PVC-free formulations: Environmental regulations and consumer preferences are driving the transition toward safer, non-toxic printing solutions. Flexographic inks are toluene-free and PVC-free, addressing health concerns associated with toxic emissions and waste.
NTNK (Non-Toluene Non-Ketone) options: NTNK formulations reduce the presence of harmful solvents, making flexographic inks safer for both operators and end-users while meeting stringent regulatory standards for food packaging.
Higher press speeds: Flexographic presses are capable of operating at significantly higher speeds, improving productivity and reducing turnaround time. This capability is crucial for meeting tight deadlines in the fast-paced flexible packaging market.
Low printing GSM: Flexographic inks enable lower ink consumption per unit area. This not only reduces costs but also contributes to a lighter overall packaging weight, aligning with sustainability goals.
Cost advantages: With reduced ink usage, limited wastage, faster processing times, and lower operational costs, solvent-based flexographic inks provide a more economical solution for high-volume packaging operations.
Challenges in solvent-based flexographic inks
Despite their many advantages, the adoption of solvent-based flexographic inks is not without challenges. These hurdles primarily revolve around achieving optimal performance in lamination processes, particularly in solvent-less and extrusion lamination applications.
Optimization for solvent-less lamination: Solvent-less lamination is widely regarded as a sustainable choice due to its reduced environmental footprint. However, ensuring that solvent-less flexographic inks provide adequate compatibility in such laminations can be challenging. Achieving excellent bond strength and avoiding delamination are critical objectives.
Lamination strength in solvent-based and extrusion laminations: While solvent-based lamination has been the industry standard for years, solvent-based flexographic inks often require fine-tuning to deliver optimal performance. This involves careful formulation to ensure the ink performs well without compromising the lamination strength.
GLS Speciality Chemicals – a pioneer in flexographic ink formulations
GLS Speciality Chemicals has been at the forefront of developing tailor-made solvent-based flexographic ink formulations. The company has consistently demonstrated its expertise in addressing the unique challenges associated with these inks, offering solutions that combine performance, sustainability, and cost-efficiency.
Custom formulations for enhanced properties: GLS specializes in creating inks that meet the diverse needs of flexible packaging applications. Their formulations excel in providing low printing GSM, high-speed compatibility, and superior adhesion properties, even in challenging lamination environments.
Polyurethane as a game-changer: The choice of polyurethane (PU) plays a pivotal role in designing flexographic ink formulations. GLS has leveraged its expertise in polyurethane chemistry to develop full PU ink formulations, which offer unparalleled adhesion, flexibility, printability and durability. These inks ensure optimal performance in both printing and post-printing processes, such as lamination and finishing.
Sustainability and compliance: GLS’s solvent-based flexographic inks are designed to meet global compliance standards, including regulations for food-safe packaging. By eliminating toluene and PVC, these inks contribute to a safer and more sustainable packaging ecosystem.
Sustainability – the future of flexographic inks
Flexographic inks, particularly solvent-based formulations, are uniquely positioned to support sustainability goals.
Reduction in VOC emissions: Solvent-based flexographic inks with NTNK formulations significantly reduce volatile organic compound (VOC) emissions. This aligns with global initiatives to lower greenhouse gas emissions and improve air quality.
Efficient resource utilization: The lower ink consumption of flexographic inks directly translates to reduced raw material usage. This contributes to a smaller environmental footprint and supports circular economy principles.
Support for renewable substrates: Flexographic inks are compatible with a wide range of substrates, including bio-based materials. This versatility makes them an ideal choice for packaging companies transitioning to greener alternatives.
Innovations and future directions
The rise of solvent-based flexographic inks is a testament to the industry’s ability to adapt and innovate. As packaging requirements become more complex and sustainability becomes more critical, the focus on research and development will continue to grow.
Advanced Polyurethane Systems: GLS and other industry leaders are investing in next-generation polyurethane systems to enhance ink performance. These systems promise improved adhesion, faster drying times, and greater compatibility with emerging lamination technologies.
Global expansion and market trends: As developing markets continue to adopt flexible packaging, the demand for flexographic inks is expected to soar. Companies like GLS are well-positioned to capitalize on this growth by providing region-specific solutions that address local regulatory and market needs.
Future of packaging lies in flexographic innovation
The rise of solvent-based flexographic inks in flexible packaging marks a vital shift toward more sustainable, efficient, and high-performance printing solutions. With their numerous advantages over gravure inks – from toluene-free and PVC-free formulations to cost savings and sustainability benefits – flexographic inks are setting new industry standards.
From a sustainability perspective, the case for flexographic inks is clear. As the packaging industry continues to evolve, solvent-based flexographic inks will play an increasingly critical role in meeting the demands of a greener, more resource-efficient future. With their unparalleled combination of performance, versatility, and environmental benefits, these inks are not just a trend but a cornerstone of modern flexible packaging.
– The authors are CEO and CTO at GLS Speciality Chemicals