Flexible Packaging
Solving the Challenges of Printing High-Opacity White Ink for Flexible Packaging Applications
Stuart Mitchell, technical director print (global OEM and sales support), Sandon Global
H
igh opacity white inks present flexible packaging printers with a delicate balancing act. Often printed on transparent films, these inks form the foundation that other colours are built on and are essential for creating bold, vibrant tones. Achieving this depends entirely on how well printers can achieve good ink laydown and opacity. Any irregularity may result in the final printed image having less vibrancy and lower shelf impact.
However, striking the balance between high opacity, minimal coat weight and low press downtime can be easier said than done. Printing white inks has long presented a challenge that requires significant process adjustments, for example, some printers attempt to improve print quality by laying down multiple layers. This can increase opacity and address pin-holing issues, but it also results in higher production costs. White ink also typically accounts for a significant proportion of a printer’s ink spend and, with the rising cost of raw materials like titanium dioxide, this approach can quickly raise the cost of doing business.
With quality and throughput increasingly important in the flexible packaging sector, selecting the right tools is key to overcoming these challenges. Ink plays an important role here with higher pigment levels contributing to better coverage. However, only so much performance can be achieved from inks regardless of how much titanium dioxide is added. This means that printers must rely on other tools, their anilox and plates, to achieve the desired results.
ANILOX TECHNOLOGY
Combining high pigment inks with the right anilox engraving can result in signifi cant opacity improvements. Sandon Global has developed High Volume Process (HVP) and Fluid FP engravings that are already helping printers reduce white ink consumption by up to 20 percent.
means that the anilox stays cleaner for longer during long print runs which can also minimise press downtime. Fluid FP is an evolution of the HVP engraving and presents an ideal solution for printing high opacity and high speed whites on flexible packaging applications. This semi-channelled engraving facilitates easier and controlled ink flow between cells while maintaining precise volume control. A smoother cell surface is achieved resulting in lower friction between the aggressive TiO2, the doctor blade and the anilox. This can also help to reduce ink misting/dusting on the printing plate.
QUALITY IN ACTION
HVP is ideal for achieving high opacity whites with a lower volume anilox. This engraving can combine high line counts and high volume, where necessary, with its unique cell design that, unlike conventional engraving, enables printing good solids and tonal areas on one plate. This technology increases the print latitude of the anilox, making it ideal for printing applications that need a high volume, such as white inks. The increased engraving resolution improves ink laydown and reduces pin holing when compared to a classic 60°. The extended cell design of HVP engravings improves the collection and transfer of ink, which also
The benefits of choosing the right anilox engraving was demonstrated by the recent collaboration between Sandon Global and prepress specialist XSYS. Trials conducted at a customer site using both HVP and Fluid FP engravings alongside XSYS’s Woodpecker Nevis screening, aimed to achieve the same quality at a reduced volume using the customer’s incumbent high opacity white ink. The results were impressive; reducing the anilox from 10.5cm3/m2 to 6.5cm3/m2 resulted in ink savings of 20 percent, as well as faster press speeds and a higher Overall Equipment Effectiveness (OEE). Printing high opacity white ink for flexible packaging need no longer be a struggle. Leveraging advanced anilox engraving technologies like HVP and Fluid FP in combination with the right ink formulation means printers can achieve superior results while reducing costs and improving efficiency. As the industry moves forward, it is clear that collaboration between anilox and plate manufacturers, ink suppliers and printers will be key to improving results and efficiency across the sector.
38
March 2025
www.convertermag.com
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