UV & EB Technology for

Flexible Packaging
Presented by:

Don P. Duncan
Director of Research
Wikoff Color Corporation

Is That All There Is?

Chemistry: UV(100)
Printing: Litho
Print Structure: Surface
Finishing: Lamination
Application: Food
Substrate: Paper

EB(100)

EB(<100)

UV/EB(100)

Flexo

Gravure

Ink Jet

Reverse

1st/Last White

UV/EB Coated
Not Food
Plastic

None

UV/EB Flexible Packaging Examples

(Ink and/or Coating)

Pet Food
Frozen Food
Laundry Detergent
Snack Foods
Gravy Bags
Retort Pouches

Paper Bags (Goldfish)

Shrink Wrap
Dry Food Pouches
Tea Bag Packets
Prepared Food Pouches

Why Use UV/EB for Flexible Packaging?

Lamination Replacements Save $

High Chemical Resistance
High Rub/Scuff Resistance
Sharper Printing
Excellent Adhesion to Films
Low Emissions a Green Story
No Hot-Air Driers
Easier Permitting for New Presses

UV vs. EB vs. UV/EB

UV

- Interstation Curing (Many Lamps)

- No Inerting (Nitrogen)
- Lamps Create Heat
- Inks Require Photoinitiator
- ~100% Solids
- Web or Sheetfed (Web for Flex. Pkg.)

EB

- Cure at the End/Wet Trap (One Beamer)

- Nitrogen Inerting
- Little/No Heat
- No Photoinitiator
- Inks <100% Solids Have Some Evaporation/Emission
- Web only (so far)

UV vs. EB vs. UV/EB

UV/EB

- Interstation Pinning (Many Lamps)

- Lower Photoinitiator Levels ?
- ~100% Solids
- No Nitrogen Purging
- EB at the End for Final Cure
- High Cure/Low Extractables with Proven Technology
- Must Buy Lamps AND a Beamer
- A Proposed Solution for Flexo, Not for Litho

UV/EB vs. Water vs. Solvent

UV/EB
WATER
SOLVENT
EC Odor
Ammonia Odor
Solvent Odor
Stay-Open
----------Evaporative Dry ---------Skin Irritant
Caustic Irritant
Skin Dry Irritant
Temp. Sens.(Cure) --Temp. Sensitive (Evaporation)-O2 Stabilizes
---------No Oxygen Effect--------More $
-----------------Less$----------------Higher Visc.
-----------Low Viscosities----------Lower Dot Gains
---------Higher Dot Gains---------

Flexible Packaging with UV/EB Litho

Clear Film

- Process and Line Colors

- White, usually last-down

Laminates

- Process and Line Colors

- Often UV/EB Coated

Paper Bags - Process and Line Colors

- Always Coated, Usually with UV/EB

Flexible Packaging with UV/EB Litho

UV

- Dry Trap / Interstation Curing

- Many Lamps
- Ink/Cure/Coat/Cure
- Cant Cure Through a White

EB

- Wet Trap / Cure at the End

- One EB Unit, After the Coater
- EB Can Penetrate White

Flexible Packaging with UV Flexo

In-Line or CI Presses (Heat Management on Wide Web)

Typically 400-700 ft./min.
Full Interstation Curing
Cure 1st-Down White Before Colors
Cure Inks Before Last-Down White
Lamination Bond Strengths Often Less than Solvent
~100% Solids Inks & Coatings
Low Emissions
Low Extractables/Migratables

Flexible Packaging with UV Flexo/EB

Coating

Inks Still Printed UV Flexo

Ink/Lamp/Ink/Lamp (etc.)/Coat/Beam
Can Run Much Faster
Requires Lamps AND a Beamer
~100% Solids Inks & Coatings
LowER Emissions
LowER Extractants/Migratables

Flexible Packaging with Solvent Inks/

EB Coating

Standard Solvent Printing (Modified Inks)

Needs Very Low Residual Solvent for Coating Adhesion
Purpose: To Replace Lamination and Save $
Requires Separate Coating Unit & a Beamer
Can Only Replace SOME Lamination
Very Successful Where Lamination is Overkill

Flexible Packaging with EB Flexo/EB

Gravure

Not Really Commercial Yet Presses Have Been Sold

EB Cure at the End, Wet Trap
Flexo & Gravure are Inherently Dry-Trapping Processes
Build Tack by Evaporation
Impressive Short Runs at DRUPA (EB Flexo)
Much Activity in EB Flexo, Some Activity in EB Gravure

Flexible Packaging with EB Flexo/EB

Gravure

Trapping Can Be Tricky

Wet in Anilox/Cylinder, Dry on Substrate, Cure
Downstream
Flexo (Raised Plate) vs. Gravure (Cylinder)
Short, Successful Runs at 1500 ft./min.
Typically No Interstation Drying Equipment (Flexo)
Typically Low Dot Gain, thus Sharp Printing

Flexible Packaging with UV/EB Flexo

Positives:

Low Residual Extractables

Possible for CI & In-Line Presses
Proven UV Flexo Ink Formulations
Able to EB Cure Without Nitrogen
Should Be Very Good for Food Packaging
Negatives: Still Have Some Photoinitiator
Buy UV & EB Equipment
Photo Levels Not Yet Defined
Photo Types/Costs Not Yet Defined
Cost/Value Proposition Not Yet Defined

Food Packaging

So-Called Indirect Food Contact

Functional Barrier
Suitably Pure Principle
Requires Partnership Between Printer & Ink Manuf.

All Technologies Can Be Suitable

Properly Applied & Dried Cured

Oil, Water, Solvent, UV, EB
Litho, Flexo, Gravure, Screen Ink Jet

All Technologies Can Be FUBARed

The Food Packaging Partnership

Ink Manufacturers Responsibility:
Ask if job is for food packaging
Clarify: Not for food contact
Ask if job will be coated
Dont use raw materials that will migrate
Dont use raw materials that will cause odor
Formulate inks to dry/cure with printers equipment
Provide optimum balance of performance & cost

The Food Packaging Partnership

Printers Responsibility:
Tell if job is for food packaging
Tell if job will be coated
Ensure drying/curing equipment is maintained & working
Measure print density Not Too Much Ink!
Suitable, low-odor Fountain Solution (litho)
Minimal F. S. levels (litho)
Test print before shipping
Standard Specs., Obvious Flaws

Food Contact

Strict Formulation Guidelines

Much Higher Risk

Limited Technologies Available

FDA Approved List

Expensive Extraction Testing

Water-Based
Solvent-Based
Ink Jet

Oil-Based Litho
EB Coating

Not Available At All* in

UV Inks
EB Inks
*Without Individual Extraction Studies

Food Contact Other Issues

Residues from Fountain Solutions (litho)

Contamination from Press Washes
Limited Press-Side Adjustments Possible
Complete Drying/Curing is Critical

UV & EB For Flexible Packaging

Not Everywhere, but is Every Day

Suitable for Food Packaging
Litho & Flexo Tend to Give Lower Dot Gains
Very Low Emissions
You Need to Need It Will the Job Pay for the Ink?

UV & EB Technology for Flexible Packaging

Thank you
PRESENTED BY

Don P. Duncan
Director of Research

Wikoff Color Corporation

don.duncan@wikoff.com

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