The Hidden Truth Behind the Rise of Water-Based Inks in Packaging.
Water-based digital inks are becoming more prominent in the packaging industry, driven by their perceived environmental benefits, improved performance, and the growing demand for more sustainable and safe solutions. These attributes are especially important in food packaging, where strict regulations dictate what solutions can be used. At the drupa event in May, the spotlight was on numerous new platforms featuring aqueous inks, even in markets that have long been dominated by UV inks.
So, why is this shift happening now, and what took water-based inks so long to gain traction?
First, it's essential to recognize that while some industries have been stagnant in recent years, packaging—especially in digital print—has remained resilient, even growing. Despite challenges such as rising energy costs, inflation, and global economic uncertainty, packaging has been driven largely by the needs of the food sector. Unlike sectors like fashion, which have seen reduced consumer demand, food packaging has continued strong. The rise of e-commerce and online shopping has also fueled the demand for packaging, with a greater emphasis than ever on differentiated print and branding. Packaging now plays a critical role in ensuring that the product's physical appearance aligns with its online presence.
One reason for the delayed impact of water-based technology at an industrial level is the technical challenges in formulating and adopting it. Some of the key hurdles have included:
Substrate Compatibility: Water-based inks may not adhere well to all substrates, particularly non-absorbent or coated materials. Ensuring reliable ink adhesion, image quality, and drying performance across a range of packaging materials often requires specially developed primers to create a consistent print surface.
Drying Time and Production Speed: Water-based inks generally take longer to dry compared to solvent-based or UV-curable inks, which can impact production speeds. Striking a balance between print speed and drying time is key to maintaining efficiency.
Durability and Resistance: On certain substrates, water-based inks can be less durable than UV-curable inks unless specifically formulated with binders to meet the stringent demands of the packaging industry.
Cost Considerations: There has long been a perception that water-based solutions, particularly in digital printing, are costly. However, advances in formulation and production processes are proving that aqueous inks can be cost-effective in the long term.
Training and Expertise: Print operators need proper training to effectively manage water-based inks. Understanding ink properties and making the necessary adjustments to equipment are crucial for consistent results, especially since water-based inks may require more maintenance than their UV counterparts.
Regulatory Compliance: Complying with industry regulations regarding ink safety and emissions is essential. Different regions have unique standards, and extensive testing is often required to prove that water-based inks meet the necessary requirements for specific packaging applications.
Why Now?
Many digital ink developers have been working on aqueous solutions for years, often in collaboration with OEM partners and suppliers. Recent advances in pigment dispersion and inkjet-grade resins for packaging substrates have helped water-based inks meet the performance expectations of end users. There's also been a strong demand across the packaging market for more environmentally friendly digital solutions. Several factors have contributed to this increased interest:
Reclassification of UV Materials: Regulatory changes have restricted the use of certain UV ink components, prompting many converters and brands to explore alternatives like water-based inks.
Evolving Substrates: New substrates, designed to meet recycling regulations, are also playing a role in the rise of aqueous inks. For example, flexible packaging is shifting toward mono-material films, which eliminate the need for metallized or laminated materials, making water-based inks a better fit due to their lower risk of migration and set-off.
Sustainability Goals: Many brands view water-based technology as a more sustainable option, incorporating more renewable materials and reducing the environmental footprint of the inks themselves. While life cycle analyses are still necessary to quantify the environmental benefits, the perception of water-based inks as a greener alternative is driving adoption.
De-Inking: Water-based inks are generally easier to remove during the recycling process, requiring less aggressive detergents. However, concerns remain about ink bleed into wastewater, and the impact on recycled material color. Ongoing innovations are addressing these issues.
Industry Collaboration: There has been significant cooperation between digital print OEMs, ink manufacturers, and software developers to create comprehensive solutions that meet the demands of various packaging segments. This collaboration has led to multiple innovations in press design, inkjet-flexo hybrid systems, inline nozzle inspection, and drying systems, all of which support the adoption of water-based technology in packaging.
Segments Adopting Water-Based Inks
Flexible Packaging: Once a challenge for water-based inks, flexible packaging is now a viable application, particularly as brands transition to mono-materials for recyclability. With advancements in ink formulations, water-based inks are now delivering high-quality prints with improved drying times and resistance on various filmic substrates.
Corrugated Packaging: Water-based digital inks are making inroads into corrugated packaging as well. Improved ink formulations are enabling high-quality printing on both coated and uncoated board for applications ranging from shipping boxes to consumer product packaging.
Folding Cartons: Water-based solutions are gaining popularity in folding carton printing, particularly for food packaging where compliance with regulatory requirements is paramount.
Labels and Narrow Web Printing: Although UV LED inks still dominate in label production, water-based inks are beginning to penetrate certain label applications, offering a viable alternative for specific substrates.
Conclusion
Water-based digital inks are becoming increasingly important across various packaging segments. As the industry continues to prioritize sustainability, both in terms of chemistry and substrates, water-based inks are emerging as a key solution. With continued innovation in ink and print technologies, water-based inks will likely play an even bigger role in shaping the future of digital packaging. Keep an eye on new solutions as the industry continues to advance aqueous technology to meet the demands of today’s fast-evolving market.