Sustainable Converting
Sustainable converting - A trialling process By Tom Kerchiss, RK Print Coat Instruments Ltd
derived from a renewable biomass such as corn or pea starch. Not all bio-materials are recyclable. Starch based materials are suitable for some applications. Derived from corn and potatoes, they are industrially compostable. Other bio renewables include PLA or poly lactic acid. PLA can be structured for rigid or flexible packaging purposes. Its worth noting that while bio-based
concerned consumers. Every industrial process is to some extent under the spotlight; industrialists of most persuasions recognise the need to develop new processing strategies and use materials that are, where possible, carbon neutral and at the end of life cycle can be safely disposed of. Fuelled by anti-plastic sentiment and the
E
fact that packaging is ever present and visible, the industry, the processes and consumables are subject to more than their fair share of criticism. Package printers, converters, producers of paper, film, foil and other materials; ink, adhesive, coating formulators have made notable progress over the past decades on the environmental front and much is now being done in working towards sustainability targets. Products and processes need to be
trialled and performance, health and safety parameters, and disposal properties assessed over the long term. It would be counterproductive and harmful to tout a material, a consumable or process and bring it to market only to find out that in the long term, the item is more harmful and less sustainable than the one it has replaced. True sustainability, that is where every
material mounted on a web fed converting machine is guaranteed free from additives and chemicals that have some impact on the environment, is more of a challenge. Using less harmful chemicals and seeking
solvent substitutes was the first step that industry took a decade or so ago towards meeting environmental as well as health and safety requirements. Printing and packaging converting had been a high- volume user of ozone depleting and harmful chemicals. Many coating and varnishes contained phthalates, heavy
38 October 2019
nvironmental compliance is no longer just a buzzword to mollify environmentalists, the media and
metals, VOCs and HAPs. Now the industry is certainly a lot cleaner than it was with the introduction of water-based coatings, inks and adhesives. Many of the materials and technologies
developed as replacements are certainly less harmful than previous products used but there are additives and components even in consumables such as water-based inks, that may, for some, not equate too well with the ethos of sustainability.
INK Let’s stay with ink for the moment. Ink may incorporate lubricants, surfactants, cross linkers, anti-foam agents, thickening agents, adhesion promoters, oxidising agents and plasticisers. Common lubricants that have been employed include PP and PE waxes, silicones, fatty acid amides and fluorocarbon waxes such as tetrafluoroethylene. Oxidising agents are useful when very high alkaline resistance is required and plasticisers also help to improve functionality in that they contribute to ink flexibility. Moving along - what about the substrate
itself? Paper and paperboard are regarded as a sustainable substrate, suitable for many applications. But even here things are not always clear cut. Paper may be coated to improve barrier properties with ethyl vinyl alcohol or EVOH. While improving the functionality of the paper, it must be borne in mind that some of the desired objectives such as sustainability, recyclability and bio- degradability can be compromised.
BIOPLASTICS Some of the most interesting product developments is in the area of bioplastics; bio based or plant- based polymers and bio degradable and/ or recyclable products, many of which are regarded as being sustainable, non-damaging to the environment and natural. Bioplastics are
materials for instance may sound as though they are an environmentalist dream material, even these have their critics. Some bio-based materials such as native or natural starch products need special pre-processing treatment prior to conversion as they can be toxic. Cassava, a seemingly ideal starch laden plant for example, is extremely toxic. Cassava also depletes soil of potash. Some environmentalists have concerns that thousands of acres often in areas covered with native forests will be given over to growing bio materials for packaging affecting food production, water tables, soil and the web of life. In the here and now, material and consumable suppliers are working with technology suppliers, converters and other supply chain providers to bring on to the market workable and sustainable packaging solutions. Packaged products must be functional and in terms of processing, tick all the right boxes, they certainly must be printable and convertible. Inks and substrates must be compatible and perform well over the life time of the product; new materials must not only meet sustainability or other targets the products mounted on and processed through a press or coater, etc, must not disadvantage the processor with regard to commercial viability. Colour communication devices, pilot lab coaters and trialling and product development tools have an important role in ensuring product viability and commercial effectiveness. RK Print Coat Instruments FlexiProof family of colour communication and proofing devices enable users and producers of flexo inks to ensure consistency of performance; determine printability; trial unfamiliar products; colour match and assess how inks and component ingredients interact with substrates over time. Additive, resin and ink manufacturers are amongst those that use the FlexiProof 100, the FlexiProof UV or FlexiProof LED UV. Other users include printers/ converters, plate manufacturers, anilox roll developers, education and research and development establishments, indeed any organisation with an interest in flexography.
rkprint.com
convertermag.com
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