Flexible Packaging
Why the future of flexible packaging is water-based
By André Altevogt, sales director packaging solutions, Follmann
converters should continue to default to solvent-based systems when a production- ready water-based option is available.
FROM INK PERFORMANCE TO PROCESS INTEGRATION
W
hen flexible packaging converters need to move away from nitrocellulose (NC)-based solvent inks, solvent-based
polyurethane (PU) is often seen as the obvious next step. It reduces reliance on NC while retaining a familiar solvent-based printing process. But, given that water-based PU technology has advanced significantly, is replacing one solvent-based system with another still the most logical long-term decision?
Water-based printing technology has advanced much faster than industry perception suggests. Earlier generations were associated with limitations around drying, adhesion, print quality and production speeds, particularly on non-absorbent films. Developments in resin chemistry, polymer design, pigment dispersion and formulation have changed that equation significantly.
Improvements have also come from greater control over the interaction between the ink and substrate. Modern resin systems can be engineered to balance adhesion, film formation, flexibility and resistance, while advances in pigment dispersion help deliver stable colour and print quality. These developments have expanded the range of film structures and applications in which water-based systems can be considered, including demanding graphics and high-speed production.
As a result, water-based PU systems can now meet the performance requirements of many demanding flexible packaging applications while significantly reducing reliance on organic solvents and lowering associated VOC emissions to less than 0.5 per cent. This changes the technology decision facing converters. It is no longer simply whether water-based PU inks can deliver, but whether
Moving to water-based requires some adjustments to the printing process, but these are now more about optimising conditions rather than overcoming limitations in ink performance. Water behaves differently from organic solvents, particularly during evaporation and drying. It requires greater drying air volume and energy to remove water from the printed film. As press speeds increase and converters work with non-absorbent substrates, dryer capacity, airflow and air velocity become important considerations.
But drying is only one part of the process. Substrate surface energy and treatment, ink viscosity and pH, anilox specification, chamber settings, press speed and dryer configuration all influence how the ink transfers, wets and forms a consistent film.
These factors highlight the importance of optimising performance within each production environment. The objective is to establish the right conditions in which the ink, press, substrate and drying system work together consistently.
Trials and technical support from an experienced ink partner can help establish the right formulation and press parameters for each substrate and application. Operator training is equally important, helping production teams understand how process changes can affect print performance and how to maintain consistent results.
The same system-level thinking should apply to cost. Comparing water-based and solvent-based technologies purely on ink price does not provide the full picture. The more relevant measure is the total cost of printing, considering energy and drying requirements, press speed, waste, cleaning, solvent handling, emissions treatment, safety infrastructure and operator requirements. For converters assessing future investments, these factors can materially change the economics of the technology decision.
A WIDER PACKAGING QUESTION Recyclability adds another dimension. Choosing an NC-free or water-based ink alone does not make packaging recyclable. The outcome depends on the complete packaging structure and the requirements of the relevant recycling stream.
However, as recyclable and mono-material structures become more important, ink selection is increasingly part of the wider packaging equation. Printing inks need to be considered alongside substrate selection, adhesives, coatings and the intended end-of-life route. With more than 40 years of experience in water-based printing inks, we have seen the technology develop from pioneering work into an established approach to packaging print. More importantly, we have seen its technical capabilities advance as formulation chemistry and application knowledge have progressed.
PREPARING FOR WHAT COMES NEXT For converters considering their next investment or ink strategy, that progression deserves closer attention.
The question today is not “Can water- based inks do the job?” but “Is solvent-based technology still the right choice?” That change in perspective matters. Water- based technology has moved beyond many of its historical limitations and matured to the point where converters should no longer have to justify considering it. Instead, the question should increasingly be whether there is still a compelling reason to choose solvent-based technology.
16
September 2026
www.convertermag.com
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