GREEN PRINTING AND PACKAGING SOLUTIONS Basics & latest improvements Aleix Mas - June 2009
CONTENTS INTRODUCTION TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS CURRENT STATUS & FURTHER STEPS COST COMPARISON REQUIREMENTS TO BE CONSIDERED RECOMMENDED APPLICATIONS CONCLUSSIONS ENVIRONMENT DRIVES FLEXIBLE PACKAGING
INTRODUCTION Packaging means. A way of life Protection and preservation of goods Information provider Silent seller
INTRODUCTION We get differentiation at POS (point of sale) trough: New Shapes and utilities Sizes Colors Graphics Innovation
INTRODUCTION PACKAGING = WASTE
INTRODUCTION Environment drives flexible packaging GROWING OF PACKAGING GROWING OF WASTE Want more protection Want smaller/individual portions Want more colors Need More Environment friendly habits environment issues drive future printing SUSTAINABILITY
INTRODUCTION 1 ENERGY CONSUMPTION 2 EMISSIONS SUSTAINABILITY PROCESS OBJECTIVES 3 WASTE
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS OBJECTIVES OF THE PROJECT ENVIRONMENT Energy consumption No emissions Safety QUALITY Higher resolution Resistance Glossier colors COST Investment Running costs Change over cost
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS PRINTING PROCESS? Printed Image is a thin (0.5 to 2 micron) layer of resin and colorant (pigment) arranged in a specific pattern. Solvents and/or water are added to the resin in order to transfer the ink from the pot to the dot These transporter has to be removed after the printed image is formed applying energy. IS THIS THE MOST INTELLIGENT PROCESS? WHY DO NOT SIMPLIFY IT?
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS HOW DOES IT WORK? With conventional printing with water / solvent based inks it is needed to evaporate solvent or water in order to trap the following color. Finally all volatile organic compounds (VOC s) have to be oxidized to avoid contamination
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS HOW DOES IT WORK? With EB curable inks there is no need of interstation drying or curing. Printing occurs wet on wet. Transfer of ink over wet ink. No back trapping. The change of viscosity and tack when ink is speeded on the substrate allows wet trapping
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS HOW DOES IT WORK? WET ON WET Only one EB curing station at end No inter-station curing or drying Wet on wet printing: - Transfer of ink over wet ink - No back trapping
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS Printing quality advantages Reduced dot gain. Better image resolution Small dot size. Better half tones and better image resolution. Full grey scale Real color pigmentation (natural colors). Less gr/m2 of ink needed Wide range of colors Extremely glossy Hard scratch and abrasion resistance Conventional EB
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS EB ink Logistics No fire laws for ink storage. Less spaced required No explosion hazard: lower insurance costs Less ink returns, returns fully re-useable without further adjustment. Less storage requirement: reduced warehouse space Increases Heptacromy (7 color process) advantages Smaller press footprint, more space in factory In-line converting is possible with EB curable coatings and adhesives. No post curing. Immediate continued process is possible (slitting). Less Ink maintenance (no solvent). Less ink waste disposal No solvent handling or distillation Cleaning with water
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS Safety is a must ADVANTAGES OF THE PROCESS: SAFETY WORK ENVIRONMENT No solvent: fumes/incineration/co2 No photoinitiators (UV) Lower noise level (no fans) Better operator working quality: higher work productivity ratio levels
TECHNICAL FEATURES & ADVANTAGES OF THE PROCESS Summary QUALITY EB increases the printing quality (dot gain, definition & resolution), high gloss and abrasion resistance. LOGISTICS No post-curing, wet on wet, no adjustments of the ink. Less waste. SAFETY Safe technology no hazardous location required. ENVIRONMENT Pollution free. No VOC, No CO2 emission legislations and energy taxes
HISTORY, CURRENT STATUS & FURTHER STEPS o Milestone 0: Project Kick off. (2004) o Phase 1: Ink - inking system development. (2004-2005) o Phase 2: Printing validation. (2005-2006) o Phase 3: First machine sold, Israel. (2005) o Milestone 1: World presentation 350 m/min, 7 colours on PE. (2006) o Phase 4: Optimizing the press & ink behavior in industrial runs. (2006) o Phase 5: New solutions trough co-suppliers: aniloxes, plates, (2007) o Milestone 2: First industrial installation, Germany. (2007) o Phase 6: Wide range of possibilities: substrates, applications (2008) o Milestone 3: May 2008: World presentation. (DRUPA 08) o 500 m/min, 7 color process different substrates. (DRUPA 08) o Another machine sold, Lithuania. (2008)
HISTORY, CURRENT STATUS & FURTHER STEPS 2009 CURRENT2 STATUS & FURTHER STEPS: Getting the best from the new Highest lineatures (75 lines/cm = 190 lpi) Faster speed (up to 500 m/min = 1.640 fpm) Adapted to new films
COST COMPARISON ELECTRICAL ENERGY Total Connected load Electricity rate TOTAL Electrical Energy Solvent based process Wetflex process GAS DRYER 265,0 Kw 306,0 Kw 0,064 /Kwh EB 0,064 process /Kwh 17,01 /h 19,65 /h NATURAL GAS Solvent based process Wetflex process GAS DRYER Total gas consumtion 21 m3/h - Natural gas cost 0,790 /m3 EB process - TOTAL Natural Gas 16,59 /h - TOTAL Energy cost 33,60 /h 19,65 /h SAVES 40% IN ENERGY COSTS
Inks: - Ink cost vs. ink performance - Expanded color gamut advantages -Improved set up Substrate: - Shorter Set up time - Thinner substrate possible Nitrogen cost: Concept Average nitrogen consumption, at 300 m/min with 1000 mm width PE/PP substrate Conversion ratio Average liquid nitrogen cost Average cost COST COMPARISON Amount 60 m3/h 1,170 kg/m3 0,130 /kg 9,12 /h COST /h 40 35 30 25 20 15 10 5 0 ENERGY: Electricity + Gas cost 37,78 /h SOLVENT 1 EB 2 PROCESS ENERGY: Electricity 19,65 /h NITROGEN 9,12 /h 9,01 /h
REQUIREMENTS TO BE CONSIDERED EB UNIT CURING EQUIPMENT SAFETY AND REGULATORY ISSUES INKING SYSTEM
REQUIREMENTS TO BE CONSIDERED EB UNIT CURING EQUIPMENT Operator s Console Accelerator High Voltage Power Supply Control Cabinet
REQUIREMENTS TO BE CONSIDERED SAFETY AND REGULATORY ISSUES - ELECTRON BEAM EQUIPMENT IS NOT RADIOACTIVE. - IT DOES NOT SPONTANEOUSLY EMIT RADIATION. - IT IS ELECTRICAL AND CAN BE SHUT OFF. - WHILE OFF, IT DOES NOT PRODUCE RADIATION.
REQUIREMENTS TO BE CONSIDERED INKING SYSTEM Special inking system: Temperature control, antifoam, stirring. Cleaning with soap and water only. Special flexo doctor blade chamber. Anilox: screen: 360 l/cm 2 volume: 2-4 cm3/m 2 Plate resolution: up to 75 l/cm
REQUIREMENTS TO BE CONSIDERED 10 COLOR EB FLEXO PRESS
RECOMMENDED APPLICATIONS & END USERS RECOMMENDED APPLICATIONS Food and Beverage Packaging Frozen and Snack foods Shrink films Stand up pouches Outdoor bags Fertilizer and garden products Lamination replacement Pet food Labels Carton printing Food packaging Detergent
RECOMMENDED APPLICATIONS & END USERS ISRAEL Electron-beam 8 color press
RECOMMENDED APPLICATIONS & END USERS GERMANY Electron-beam 8 color press
RECOMMENDED APPLICATIONS & END USERS LITHUANIA Electron-beam 10 color press TÍTOL
CONCLUSSIONS EB printing today is technically capable. Now is time to start commercializing. There is a need to educate the market. Advantages are there and promoters will enjoy them. WE start a new technological era YOU can be one of the promoters
EB press at Drupa 08, world speed record 500 m/min (1.600 fpm)
Thank you very much for your kind attention Aleix Mas Email: amas@comexigroup.com