THE FLEXO PRINTER’S GUIDE TO

SUSTAINABLE PRINTING
What is Sustainable Printing?
Everyone in the industry wants to know: What are the essentials of sustainable
packaging? According to the Sustainable Packaging Alliance, or SPA, a “sustainable”
package must meet the following requirements:

• Effective: Provides value and supports responsible decision making.

• Efficient: Uses and maximizes green packaging materials.
• Cyclic: Uses eco-friendly packaging materials, technologies, and inks.
• Safe: The package poses no harm to human health or the environment.

What Does Sustainable Print Design Mean for

Flexo Printing?
Many industries are moving toward sustainable business practices. Whether they’re
trying to reduce emissions or refine their manufacturing operations to minimize
material waste, they’re working toward a more eco-friendly future.

Flexo printing is also transitioning toward a more environmentally friendly future.

What began with green packaging has become a more comprehensive effort toward
sustainable flexo. This will provide long-term environmental benefits at all stages in
the printing process.

Having a sustainable print design means thinking not only about the in-house practices
like volatile organic compound (VOC) capture, but also considering the end use of your
product. Where will it end up? How long will it take to biodegrade?

All of these considerations should be addressed in your sustainable printing strategy.

Developing a
Sustainable
Printing Strategy
The sustainability conversation usually
starts with “going green” initiatives.
Going green and being sustainable aren’t
mutually exclusive endeavors; in fact,
they largely complement one another.
Think of going green as one step in
an overall sustainability effort. They
each approach eco-friendliness from a
different perspective.
Going green begins with end-of-use
environmental friendliness in mind, and
it tends to focus on immediate steps for
promoting eco-friendly habits.
For example, the classic going green
strategy is “reduce, reuse, recycle.”
Reduce what’s used, reuse existing
products if possible, and recycle those
that can’t be reused. While these
are effective habits for decreasing
environmental impact, they’re vanilla.
Almost everyone does them.
Companies tout their triple-R efforts, but
real sustainability starts with awareness
and design. Going green is the last stage
in an overall sustainability strategy.
Steps for a Sustainable
Packaging Strategy
Developing a comprehensive
sustainability practice can be daunting,
there’s so much to consider!
Start with the basics:
• Developing an awareness of
sustainability concerns/opportunities
• Sustainable packaging design
• Green sustainable packaging materials
• Product end-of-life
It’s OK if you don’t think of every little
detail right out of the gate. Many
sustainable packaging strategies are
revisited, added to, and adjusted to suit
new goals over time.
Thinking About
Sustainable Flexo
The first step to fixing a problem is to
recognize there is one, right?
Take a look at your company’s carbon
footprint. How much waste are you
putting out? Where do your products end
up after customers are done with them?
Are there more sustainable practices you
could be using?
Then, make a SMART goal (specific,
measurable, achievable, realistic,
time-bound). An example would be
decreasing your company’s waste from
flexo printing operations by 40% in 3
years. You’re more likely to follow
through on that target instead of simply
saying, “Let’s be more eco-friendly.”
The transition to sustainability requires
awareness and knowledge. Learn all the
ways sustainability can ultimately be
infused into your own printing processes.
Sustainable
Packaging Design
When designing a product, the
customer’s needs are forefront in
your mind, right? Why not slip in the
environment in there too? All great
sustainability packaging strategies start
as an idea and grow from there.
Think about the processes needed to
make your product. Are they wasteful? Is
there a process that’s less wasteful but
still meets the same end goal?
What’s the end-use of the product? Will
it go to a landfill or be recycled? Can
customers use it around the house?
Most Sustainable
Packaging Materials
Obviously, materials are a big part of
the sustainability movement. Most
customers want biodegradable and
reusable packaging, so the industry
has no choice but to deliver.
Today the industry offers a variety of
sustainable product packaging solutions,
including sustainable materials for food
packaging.
Some of the most sustainable packaging
materials today are the same ones
you’ve heard about for years:
• Sustainable paper/paperboard
• Recycled corrugated cardboard
• Biodegradable plastics
Many plastics are now recyclable at
drop-off recycling locations. PVC (#3)
and PS (#6) are usually the top plastics
on any list of sustainable packaging
materials.
We’ll talk about sustainable substrates
and inks later on, as they’re a big part of
the sustainability conversation.
Product End-of-Life
Technically, when your product rolls off
the lot, it’s not your problem anymore.
You’re done with it. Sayonara. Adiós.
Wrong. Your flexible packaging is just
as important when it’s out on the market
as when it’s on the presses. Think about
how much product you make yearly. Got
a number? Now, think about all of that in
a landfill somewhere. Not a pretty sight,
huh?
Remember the quintessential “green”
tactic from earlier – reduce, reuse,
recycle? Well, your product should
reduce landfill waste, be reusable, and
consist of recycled materials that can be
recycled again.
Many companies recollect their
packaging after it’s been used so they
can clean it and put it to use again.
Improving Flexo Processes with
Sustainable Packaging
When you’re producing a consumer product, it’s nice to be able to slap on a sticker
that says “Made With 100% Recycled Material.” In today’s climate, customers are more
likely to buy products made with sustainable packaging than those made without.

So, obviously, the largest consideration for flexo printers looking to turn to a more
sustainable printing practice is the materials used. These include:

• Inks
• Substrates
• Coatings & Adhesives
Sustainable Printing
Materials | Ink
While there’s no 100% sustainable flexo
ink, there’s certainly a hierarchy of inks,
with some being more eco-friendly
than others.
The four prominent sustainable flexo
inks for packaging include:
• Water-based inks
• Soy/vegetable inks
• UV inks
• Algae inks
Water-Based Inks
If you’re serious about sustainable
flexo inks, you’ll want to stay away from
anything solvent or oil-based, or inks
made using petroleum.
Water-based inks are a great alternative,
as they contain lesser amounts of
volatile organic compounds (VOCs)
and more simple ingredients. Water-
based inks are probably the oldest
eco-friendly ink around. They’re popular
for highly absorbent substrates, like
corrugated paperboard.
Prints still look great with these types
of inks, so you’re not sacrificing quality
for sustainability. Plus, they’re easy to
clean, simple to store, and compatible with
elastomer image carriers
Soy/Vegetable Inks
Vegetable-based inks are typically
derived from an organic compound, like
corn oil or soybeans. They’re designed to
print in a way that significantly reduces
the release of VOCs Plus, the natural
components used to make these inks
are easier to recycle and break down
faster than conventional inks.
UV Inks
Now’s a good time to mention the
distinction between different kinds of
inks. Generally, inks are categorized into
volatile inks and curable inks.
Volatile inks cure via absorption, and are
the most common type of ink. Curable
inks, on the other hand, have very little
absorption and dry using an ultraviolet
light or electronic beam.
UV inks are dried using UV light. These
inks dry almost instantly and release
99.5% fewer VOCs. Plus, curable
inks eliminate the need for additional
coatings and protectants, unlike
conventional volatile inks.
Algae Inks
Often dubbed “the most sustainable ink,”
algae ink actually has a negative carbon
footprint and is said to reduce carbon
emissions by up to 200%.
It’s also resistant to UV light. This
technology is still fairly new, however, so
there’s reason to believe that we’re just
starting to tap into its full potential.
Sustainable Printing
Materials | Substrates
When it comes to the most sustainable
substrates, you have a surprising number
of options.
While paper and corrugated board are
perhaps the best sustainable packaging
examples for their recycling benefits,
new materials are being developed with
similar benefits. Many people point
to plastic flexible packaging as a key
culprit of packaging waste. However, it’s
important to note that more and more
modern packaging films are recyclable
at store drop-off locations.
Some plastic films are even compostable
or biodegradable to reduce their strain
on the environment. Plastic films may
not yet be a widely accepted technology,
especially compared to corrugated
board and paper, but advances in plastic
packaging have made them less of a
target for environmentalists.
Here are some of the most innovative
and effective sustainable substrates for
flexo printing.
Recycled Paper and Corrugated
Paper comes from trees. So it stands
to reason that producing more paper
means cutting down more trees, right?
Not necessarily. Recycled paper,
cardstock, and corrugated cardboard
take previously manufactured paper
products and transform them into
something new.
But we’re not just saving trees by
recycling old paper products. For every
ton of recycled paper, we save 380
gallons of oil, 7,000 gallons of water, and
4,000 kW of energy. It’s much easier to
turn old paper into new paper than it is to
turn wood pulp into paper.
When it comes to flexo printing, recycled
paper and corrugated aren’t that different
from their brand-new counterparts. Same
printing process, same press.
One important consideration with
printing on recycled material is the kind
of ink to use. If there isn’t a closed-loop
recycling process, the end product might
end up in a landfill or -- regrettably -- as
litter. In that event, is the ink bad for
the environment? Deinking paper and
corrugated materials is a step in the
recycling process, but if the material
never reaches that step, then what
happens?
If you plan on incorporating
sustainable/recycled substrates, also
consider sustainable inks, coatings,
and adhesives.
Biodegradable and
Biomaterial Plastic Films
Plastic is a very popular and versatile
substrate because it’s non-abrasive
and easy to manipulate. However, as
everyone knows, plastic takes a long
time to biodegrade and there’s a lot of
waste in the plastic-making process.

When considering plastic, ask these

questions:

• Is it made with renewable ingredients?

(Plant-based, not petroleum-based)
• Is it safe for the environment after it
reaches end of life?
• What is the manufacturing process to
make the plastic? Is there a lot of waste?

Plastics made from biomaterials offer

a solution to the traditional plastic
dilemma. Cellophane, while still not the
most eco-friendly plastic, is made from
cellulose, a plant fiber.

There are many other biodegradable

plastics out there, including Pace
BIOGRAGH.ics, Spartech Rejuven8, and
Ultraflex BIOflexFL.
Sustainable Printing
Materials | Coatings &
Adhesives
Inks and substrates are just two aspects
of your flexo printing process. You’ll
also need sustainable coatings and
adhesives.

VOCs are just as much a consideration

with adhesives as they are with inks.
Typically, synthetic adhesives or coatings
will emit more VOCs, so sustainable
designers are moving toward more
renewable adhesive derivatives.

For example, gluten and casein are

effective adhesives, but they’re derived
from animal proteins, so some people
avoid using them. The most efficient and
sustainable adhesives are made from
plant proteins, like potato or corn starch.
Envelopes use reactive adhesives on the
flap, where liquid activates the potato
starch, making it sticky.

Also, consider the recyclability of your

adhesives. Will they break down without
needing to use harmful chemicals?
Sustainable Printing
Materials | Equipment
When people talk about sustainable
printing, the inks and substrates take
the forefront of the conversation.
And of course, using water-based
inks or bioplastics is a great “green”
improvement for any flexo printing
practice.
However, to have a comprehensive
sustainability plan, the flexo printing
equipment can’t be ignored. This
includes your
• Pressroom
• Image carriers
• Inking equipment
• VOC capturing methods
The Pressroom
As flexo printers already know, some
presses aren’t built to print on certain
substrates. Assess your presses before
you commit to using a sustainable
material you don’t have the capability to
print with.
Polyethylene is a particularly difficult
substrate to print on because it’s so thin.
But, it’s recyclable and reduces plastic
waste, so it might be worth investing in a
new press.
But presses aren’t the only technology
you should consider improving.
Most conventional flexo operations dry
the prints with heat, which is almost
always powered by a nonrenewable
resource. There’s a lot of wasted energy
from escaping heat, and burning fuels
can create additional pollution.
Using air compression is a more
environmentally friendly option for drying
your prints. This method can cut energy
costs by 50% and can supplement
traditional drying methods for even
faster drying speeds.
Image Carriers
What image carrier are you using?
Photopolymer plates, maybe?
Did you know that photopolymer plates
can be recycled and reused in other
plastic products? This is a great way to
cut down on waste and save costs for
brand-new equipment.
However, photopolymer plates aren’t the
bee’s knees in terms of eco-friendliness.
Trace amounts of mercury, lead, and
other harmful elements are in plates.
Often, these chemicals get washed down
the drain when exposing the plate.
Integrating a sub-micro mesh filter
into the waste water disposal
system will go a long way toward
reducing environmental impact from
photopolymer plates.
But, what if there was a better image
carrier that didn’t need so much hand-
holding?
Elastomer Sleeves
Elastomer sleeves are an eco-friendly
alternative to photopolymer plates,
made with a high-quality rubber for
longer-lasting print runs. Also, elastomer
sleeves ensure a quality print job the
first time -- no wasteful second run
necessary.
Sustainability goes beyond just ensuring
you’re using eco-friendly substrates, inks,
and more. It’s also about making sure
your equipment is working up to its full
potential. Elastomer sleeves keep flexo
presses running better for longer, while
also being:
• Fast and easy to clean
• Long-lasting
• Highly detailed
• Simple to install
Anilox Rollers
Anilox rollers are essential for ensuring
an even spread of ink on your image
carrier, and they’re often made of steel
and a ceramic coating. There aren’t many
options for eco-friendly anilox rollers, but
that doesn’t mean there’s anything you
can do!
Since the rollers are constantly coming
into contact with ink, it’s important to
clean your rollers, right? How you clean
your anilox rollers is where you can
make a more environmentally conscious
decision.
Common cleaning practices often
involve harmful chemicals that release
VOCs and require extensive capturing
and filtering systems.
But, there are a few ways to clean anilox
rollers that pose a small environmental
impact, or none at all! Take water-based
chemical cleaning or laser cleaning as
examples.
Ink Equipment
Obviously, materials make up most of the
conversation around sustainable flexo
printing. However, that doesn’t mean
processes and equipment are entirely
excluded.
Ink control automation is one way to
strike the right balance between quality
and sustainability. Simply put, ink control
automation works to streamline and
balance printing operations to reduce
waste, using only the exact amounts
of ink. In addition to using less ink
and contributing to a more all-around
sustainable solution, implementing this
type of solution can also help reduce
overall printing costs.
VOC Capture
There are two ways that VOC emissions
enter the atmosphere: evaporation
from inks, coatings, and adhesives; and
evaporation from cleaning materials. To
protect the health of your workers and
the environment, implement the correct
VOC emission control methods. The
most effective ways are...
Containment
Capture systems are a critical
component of maintaining a VOC-
free work environment and limiting
emissions. These control systems are
designed to capture solvent-laden air
and push it toward a control device. The
system often includes components like:
• Fume hoods
• Floor sweeps
• Permanent total enclosures (PTEs)
PTEs ensure that your workers are kept
safe from VOCs, and by enclosing high-
risk equipment or areas, you can work
toward 100% capture efficiency.
However, PTEs are not always necessary.
Many newer flexographic or rotogravure
presses have integrated capture
systems, often with 85-90% capture
efficiency.
Control Devices
There are many control devices available
to integrate into your warehouse for
VOC reduction. Today, control devices
operate with about 95% efficiency in VOC
regulation. Most control devices contain:
• Carbon absorbers
• Thermal oxidizers
• Catalytic oxidizers
Carbon absorption allows the capture
of VOCs as a condensed liquid and
promotes reuse or better recycling.
Finding out what control device is best
for your workspace depends on the
size of your building; the type of inks,
coating, and adhesives you use; and how
much solvent-laden air needs treated.
Low-VOC Inks, Coatings,
and Adhesives
While several methods have been
developed for the capture and recycling
of VOCs, there’s a way to prevent VOC
emission in the first place.
Some flexographic and rotogravure
printers use water-based inks, which, as
we mentioned, are more environmentally
friendly than other conventional inks.
Water-based inks contain alcohols
or glycol ethers that improve flow
characteristics and lower surface
tension, and if implemented in printing
use, can significantly lower or eliminate
VOCs.
However, depending on your printing
systems, you may need to retrofit your
equipment to be able to use water-based
inks. Flexographic and gravure printing
uses hundreds of different inks, coatings,
and adhesives -- there’s bound to be an
eco-friendly available for your printing
needs.
 Who is
Luminite?
Luminite is a flexographic printing
equipment supplier located in
Bradford, Pennsylvania.

We’ve developed innovative flexo

products since our inception in 1926,
including the patented Load-N-Lok
elastomer air sleeve. These elastomer
image carriers are more eco-friendly
than other conventional printing
methods because they decrease the
need for harsh chemicals and last
much longer.

If you’re looking for image carriers

at the forefront of flexo technology,
Luminite has you covered.

Web www.luminite.com/
Phone 888-545-2270
E-Mail sales@luminite.com