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In-Line Printing and Laminating with EB Curing for Packaging
Applications
Im Rangwalla Radtech Europe 2013
Basel Switzerland
Global Flexible Packaging Market By Region
Total $ 65 Billion Source FPA N America
30 % N America
7% C&S America
25% Europe
5% Africa M East
33% Asia Pacific
Dollar Value of US Flexible Packaging Market 1998-2012
Year
1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
$ Bi
llion
s
12
14
16
18
20
22
24
26
28
Flexible Packaging Industry Major Processing Categories
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Printing Laminating Coating Extrusion
LAMINATING ADHESIVES CURRENTLY USED
Adhesive Type
Market Share
Growth Typical Chemistry
Typical Cure Time
Water Based Adhesives
10–15%
Flat
Isocyanate
1-2 Days
Solvent Based
Adhesives
50–60% Flat – Decline
Isocyanate, Ethyl Acetate
1-2 Days
100% Solids Solventless
25–40% Growing
Isocyante 1&2 Part
3 Days
Advantages of EB laminating Adhesives
• Instant Cure: Immediate shipping available • No Toxicity Concerns of Isocyanates or
residual Aromatic Amines • In-Line Printing and Lamination • Compatible with commercial inks • Excellent laminate appearance
EB LAMINATING ADHESIVES ADVANTAGES
FEATURE
BENEFIT
INSTANT CURE
LESS LABOR- NO WAREHOUSING
INSTANT CURE
LAMINATE TO EDGE
INSTANT CURE
REAL TIME QUALITY CONTROL
INSTANT CURE
REDUCE INK COST, ELIMINATE ADHESIVE ETCHING OF INK
TAILOR MADE VISCOSITY, WIDE RANGE APPLICATION METHODS
CAN USE EXISTING COATING EQUIPMENT
EB Laminating Adhesive Market Value/Performance
HighRetort,
Aqueous Foods
MediumMeat&Cheese,
CoffeeSnacks
LowBottle labels, Dry Foods
EB
Flexography solvent Based Ink With In-Line EB Laminating
EB laminating Adhesive Technology Summary
• Excellent film bonding properties has been achieved with multiple substrates. BOPP, PET, LDPE based sealant films, Aluminum Foil, and Paper Board.
• Excellent bond performance with commercial flexo and roto-gravure ink systems
• Laminate exhibit good water, and food resistance. • Suitable for food packaging FDA compliance no taint or odor. • Retort Compliance still a challenge • Cost compatible with other incumbent time cured adhesive
technology • Capital Cost Justification Challenging
Commercial Status of EB Laminating Adhesive Technology
• Commercial In-Line solvent based rotogravure printing and EB Laminating for Dry Detergent. – Structure OPP/EB adhesive/GravurePrint /PaperBoard – OPP Provides MVTR
• Commercial In-Line solvent based Flexo Printing and EB Laminating for Paper Reams – Structure OPP/Solvent Based Print/OPP
• Commercial In-Line water based stack Flexo and EB laminating Adhesive for BaseBall Cards – Structure OPP/WaterBased Flexo/Metallized OPP
• Line speeds over 350mpm achieved • Good Success With Commercial solvent and water based
Flexo & Gravure Inks
Challenges Faced By Converters
• Runs Getting Shorter • Market Demand For Sharper and more Graphic
Changes • JIT Reduce Inventory and Run Lengths • Graphic Quality Keeps Increasing • Frequent Design Changes • Cost Needs to Come Down • Color Match Globally • Sustainable Packaging
Technical Developments
Gravure for flexible packaging No new developments
Flexo for flexible packaging •General flexography technology, Photo polymer plate dvlpmnt • Water based EB Flexo • EB Cured-Flexo Ink
Sheet-offset for labels and folding cartons
No new developments
Web-Offset for folding cartons and flexible packaging
Variable formats/repeat Central Impression CI-8
Variable Sleeve Offset Printing (VSOP)
With EB Curing
Using sleeves like in flexo
Advantages of EB Curable VSOP Technology • Excellent Print Quality. Like Gravure • Sleeve Technology allows Fast Response from
Printer to Customer • Multiple Ink Suppliers • Competitive For Short Runs • High Speed 400 meters/min Possible • Print on Broad Range of Substrates • Established Print Technology • NO VOC and Food Packaging Friendly • In-Line Printing Coating or Laminating
VSOP PRESS EZCure-I DF EZ110/90/1000
Status of EB Curable Offset Print
Technology
• Multiple lines operating in Europe and America for Food and Non-Food packaging.
• Broad Range of Substrates. Mostly Paper & Paperboard. Some Plastic Films.
• Many Global Offset-Ink Suppliers. • Commercial Production at 350 meters/min • Web Widths 850- 1250mm
– Print Repeat Lengths 381- 762 mm & 570-1120 mm
CI-8 EB Offset Technology
Converter Printing Comparison Flexible Packaging
Print Type
2007 2009 2011
FLEXO 67% 65% 64% GRAVURE 11% 10% 11% OFFSET 1% 1% 5%
UNPRINT 22% 20% 19%
EB CI-Flexo Technology Development
Patent or Application
Number
Filing Date
Assignment Abstract
US 5,690,028 June, 1996 Cavanaugh Corporation
USA
Method of achieving wet trapping by heating the subsequent ink to reduce viscosity
US 6,772,683 Feb, 2002 Sun Chemical USA
Method of achieving wet trapping by evaporating non-reactive diluent and increasing viscosity of the
applied layer
WO/2010/071952 Dec, 2009 Technosolutions Brazil
Method of achieving wet trapping by evaporating a non- reactive
diluent and forming an organo gel in the applied layer
WO/2011/091364 Jan, 2011 Sun Chemical USA
Method of achieving wet trapping by controlling the storage modulus of the
ink. Each applied ink layer will have decreased modulus
Advantages of EB Curing CI-Flexo Technology
• NO VOC – NO Incineration or Recovery System – Very Low Energy Consumption Compared to Heat or UV
Curing • Curing/Drying Systems
– No Ovens – No Inter-station Drying – No Remaining Solvents
• Stability/Handling – No Dry-In – No Press Side Adjustments – Water Washable
Advantages of EB Curing CI-Flexo Technology EB CI-Flexo
Process
• In-Line Printing and Laminating • Performance Advantages
– High Gloss – High Definition Graphics – Dot Structure and Dot Gain – Higher Line Screen Up to 70 L/cm
• High Color Efficiency – Finer Anilox – Less Ink Consumption
• Crosslinked Systems – Instant Cure – Scratch & Solvent Resistance – Heat Resistance
• Food Packaging Compliant – No Photo Initiator – No Odor/Taint
Status of the EB CI-Flexo Ink Process
• Installations in Americas and Europe For Food & Non-Food Packaging
• Multiple Ink Suppliers & Technologies – Wet trapping by evaporation of non reactive diluent & forming
viscosity gradients in trapped layers. – Wet trapping by evaporation of non reactive diluent & forming
organo gel. – Wet trapping by thermally drying water in between decks and
curing finally with EB to improve printed ink properties • Retrofit For Existing CI-Flexo Press. • EB Press with NO Dryers for first 2 technologies • Broad Range of Substrates. Paper, PE, OPP, PVC,
Aluminum Foil • On-Site Demonstration available at Major Flexo Press
Manufacturers.
In-Line EB Printing and Laminating Makes Sense
• Instantaneous Cure Provides JIT Market Demand • EB Cured Flexo and Offset Inks Provide Higher Print & Graphic Quality • Quick turnovers and make ready with EB printing and in-line laminating
provides quick turn around for shorter runs • EB Curing Offers Solventless Printing and Laminating with the lowest
Carbon Foot Print • Capital Cost of EB equipment is shared by curing inks and laminating
adhesives together • In situ curing of inks & laminating adhesive using similar chemistry poses
less challenges than laminating EB cured inks with conventional PU type adhesives and vice versa.
• New low voltage EB equipment are designed for lowest Power Consumption and least affects on substrates
Thank You Vey Much For Your Attention