The company’s Prism sustainability framework includes a range of targets such as circular economy product development, reducing operational impacts, and building a diverse workforce. Plans include Flint Group’s recent commitment to the Science Based Targets initiative (SBTi), with the company reducing carbon emissions in line with the 1.5 C scenario set out in the goals of the Paris Agreement.

Matthew Rowland-Jones, sustainability officer at Flint Group, said, “As the focus on climate change grows, brands seek packaging and label formats which are more sustainable to support their objectives. In today’s highly competitive market, printers need confidence that their vendors can help them lead in sustainable packaging via responsibly sourced, sustainable materials. Flint Group’s new Prism framework does just that. With a new set of targets and KPIs, we’re outlining how we will pave the way for even more sustainable products.”

In the same way a glass prism separates white light into different colours, the company’s Prism framework breaks the complexity of sustainability down into three essential parts: products, people, and the planet. It is designed to embed sustainability into the business, focusing on the most critical issues affecting the organization, its customers, and stakeholders, and specifically by designing products for the circular economy, helping customers be more efficient, and lowering the carbon footprint of its core products.

The partners to the initiative recognize it is only through cross-industry collaboration that progress can be made. Founded in 2019, German startup Wildplastic aims to clean the environment from plastic waste. In co-operation with communities of collectors, the start-up works globally to collect “wild” plastic from beaches, landfills, and illegal dumpsites. In spring 2019, Wildplastic started selling the first trash bag that is 100 per cent made of recycled plastic. Currently, their focus is on sourcing low density polyethylene (LDPE) such as bubble wrap or certain food packaging. LDPE cannot yet be widely recycled, so the market collection incentive for it is still limited. Wildplastic wants to change this by creating a demand for this material and showcasing the potential of post-consumer LDPE recycling. After collection, the plastic is transported to a recycling partner who washes, melts and processes it into granules. These recyclate granules are then sent to a production partner and used as a substitute for virgin LDPE material. This material is then used to create trash bags and mail bags. A broader scope of applications may be possible if the materials could be successfully deinked first.

In 2021, Wildplastic and the Institute of Circular Resource Engineering and Management (CREM) of Hamburg University of Technology (TU-Hamburg) started a co-operative research and development project, financed by the Investment and Development Bank of Hamburg (IFB), to study the feasibility of improving the quality of LDPE-recyclates from post-consumer sources. Evonik is supporting this project as a co-operative partner.

“We started to conduct research on deinking of post-consumer plastic waste with Wildplastic about one year ago. As a technical university, it is important to carry out meaningful research relevant to the real-world problem. From our project, we have learned that a successful circular economy only works by motivating all the stakeholders involved. Siegwerk, as the producer of printing ink, can play an important role in this context since it brings the producer’s perspective to solve the problem in the beginning,” said Jinyang Guo from the Institute of Circular Resource Engineering and Management (CREM) at TU- Hamburg during a kick-off meeting between the partners in November 2022.

Siegwerk is supporting Wildplastic in this initiative by providing the deinking chemistry and knowledge to enable the creation of clean recyclates. In order for successful deinking to occur, a precise combination of the right ink chemistry, the right deinking detergent and the right process needs to be applied. Inks on packaging can often be a hinderance to recycling, as the inks degrade during the recycling process and can contaminate the recyclates, leading to unpleasant odours or unsightly colours. Even if the inks are not totally removed, the opportunities for recycling are increased exponentially.

“It is a pleasure to work with our partners from Wildplastic and from the University of Hamburg on this topic. We have a strong can-do attitude in common. The scientific perspective and the conscientiousness contributed by Jinyang helps us to maintain a fact-based and objective view, not only in the design of experiments, but also in the interpretation of results. Wildplastic has the ambition to benefit from deinking in their recycling activities in just a few months and brings in an industrial perspective,” said Ingo Fehr, senior project manager at Siegwerk.

“We have started this collaboration with Jinyang and the University about one year ago following our deep interest to find a solution for specific washing needs for highly challenging post-consumer plastic film materials in a small scale batch operation. From day one we have worked together in a very open and solution-orientated way and with shared passion. It’s all about getting the right people together, therefore we are extremely happy to share our results and to extend our collaboration with the team at Siegwerk,” said Wildplastic co-founder Dieter Gottschalk.

Over the last three to four years, the world’s environmental consciousness was raised by young activists marching on Fridays to draw attention to the need for reduction of greenhouse gases in all sectors of life. The task to improve, however, is not for one person or company alone, but for many to think within their areas of influence and expertise whether they can contribute positively toward this goal, and then take steps to do so.

Although flexographic plates only represent a tiny fraction of the overall package environmental footprint impact, it should nevertheless be the goal of everyone using these plates to not simply accept the current status quo, but to constantly strive to push boundaries higher and higher, leveraging philosophies such as Kaizen, a Japanese strategy where employees at all levels of a company work together proactively to achieve regular, incremental improvements to the manufacturing process.

In flexo platemaking today, a variety of different technologies are used in various markets. Some are less hazardous, such as water-wash or thermal plate making, but the vast majority, representing approximately 70 per cent of all flexographic operations, use hydrocarbon-based solvents to wash out their flexo plates. This not only requires a specialized production room environment, but also may contribute to a hazardous ambient working environment in the platemaking room if not handled well.

Based on that data, the author has looked at a large segment of solvent wash platemaking users in our industry to find ways to suggest how these operations can modify their platemaking process, helping them to take action to reduce their environmental footprint.

The magic trick and answer to improve the environmental footprint is: “Plate relief depth reduction.”

Looking at flexible packaging, one of the largest segments of flexographic printing representing a global market share of approximately 25 to 30 per cent, a standard plate relief depth of 0,6 mm with a 1,14 mm (45 thou) plate gauge is being used. The relief depth, however, is changing region by region. Whereas Europe was more conservative in allowing a large margin of tolerance between the printing element and the base floor, on the South American continent, printers have long used a plate relief depth of 1/3 of that standard plate thickness, with a plate relief depth of about 0,35 mm being more commonly used in that hemisphere.

What are the advantages of reducing the plate relief depth and what are the limits of technical tolerance before the floor of the plate hits the substrate? A printing project was set up to confirm the limits and highlight potential improvements.

A full platemaking and printing trial was arranged using different plate relief depths starting at 0,6 mm and going down to 0,1 mm for a 1,14 mm (45 thou) plate.

Plate back exposure

The plate back exposure time needs to be elongated to polymerize more plate material. For a relief depth of 0,6 mm a UVA energy of approx. 330 mJ is needed and for 0,3 mm an energy of 1000 mJ.

Exposure amount in mJ.

This back exposure time can be partially compensated by a reduction of the main exposure time as the plate is largely polymerized.

As an example, for a relief depth of 0,3 mm, the back exposure time is elongated by approximately a factor of three.

Plate washout time

The industry uses a large variety of washout solvents, and it is therefore recommended that flexo platemaking operations check their individual conditions using their equipment, plate and solvent specifications.

Top relief depth vs. washout speed.

For a good plate washout time, we always calculate a safety margin of 0,2 mm and add that to the plate relief depth. This safety margin takes account of the fluctuation of washout solvent quality and should be added. So, in our example of a relief depth target of 0,3 mm, we would look at a 0,5 mm washout relief depth with the safety margin included. In that case, the washout time would be approximately 165 mm/min for a relief depth of 0,3 mm vs. 90 mm/min for a relief depth of 0,6 mm. The washout speed improvement would be approximately 80 per cent if we target a relief depth of 0,3 mm.

Polymer waste in the washout solvent

Reduced polymer waste material on shallower relief depth plate.

In the above illustration, it is easy to see that a flexo plate with a relief depth of, for example, 0,3 mm is washed out with 50 per cent less polymer waste in the washout solvent compared to a flexo plate with a relief depth of 0,6 mm. The standard solvent processor today replenishes solvent on the basis of polymer content or viscosity of the washout solvent. Hence, a company which reduces the plate relief depth from 0,6 mm to 0,3 mm can wash two plates instead of one before solvent replenishing in the tank is required. This is a massive saving of 50 per cent of solvent in your operations just by lowering the plate relief depth, and it is a big step toward operating with a better carbon footprint.

Plate drying time

Plate drying time at 60 C.

The plate drying time depends on the length of time the plate has been in contact with the solvent. Hence, with a washout speed of 90 mm/min, a plate will be more swollen with solvents than a plate, which was washed out at much faster speed. Subsequently, if the plate is submerged into solvent at a much faster processing speed, the recovery time to nominal plate thickness in the dryer is quicker than for a plate that spends a longer time in the washout equipment.

In the example of a relief depth of 0,6 mm, the plate washout speed was adjusted to 90 mm/min, giving a plate drying time of approximately 120 min. The washout speed of a plate washed with a relief depth of 0,3 was 165 mm/min, resulting in a plate drying time of approximately 75 min to recover back to nominal thickness. This also equates to an approximate reduction in energy use by the dryer from 4,8 KW down to 3 KW per m² of plate material used.

Printing test

Despite all the solvent, time and energy savings, the biggest concern, of course, is whether the plate floor would print using a shallow plate relief depth.

In the example below, we worked at the DFTA-TZ facility of the Stuttgart University and printed the different relief depth plates with a setting of 70 microns extra pressure over Kiss Print. Anilox pressure was 60 microns of extra pressure.

The numbers on the top of the print sample indicate the different relief depths of 0,6 mm on the left and 0,5 mm on the right.

We compared the dot gain curves between the different plate relief depths and concluded all curves are very similar and can be used without the need to make adjustments to printing curves. However, a small adjustment might be considered by the local repro on a case by case basis as we could not confirm the dot gain for longer run production jobs.

Dot gain curves at different relief depth

In addition to the print dot gain curve, we also analyzed the highlight dot anchoring on the plate floor. As can easily be seen in the previous illustration repeated below, the dot anchoring is much more stable compared to the plate with higher relief depth, giving added rub resistance to the plate, which is particularly useful for long runs. Hence, the plate quality is increased as well.

Improved dot anchoring stability on shallower relief depth.

To the surprise of the participants, while we thought that the 0,1 mm relief depth would be impossible to print, that was not the case. There was a small area at the tail edge of the plate which actually printed from the plate floor, but the rest was fine. For that reason, we do not recommend using a plate relief depth of 0,1 mm. Going to the next higher relief of 0,2 mm, it was confirmed this relief depth poses no problem when printing, nether in terms of dot gain curve nor in terms of plate cleanliness.

For customers who want to push flexo printing to the limit with modern machinery and high printing quality, this is certainly a relief depth to consider. For all other users, we would recommend the safer plate relief depth of 0,3 mm to 0,4 mm. This maintains enough tolerance to avoid any possible printing trouble, it considerably improves plate quality and, most importantly, improves the environmental footprint of the platemaking production.

Conclusion

The message of this practical exercise is that anyone can make a significant contribution to the environmental footprint of platemaking in their company at a local level by taking these described actions while improving the overall quality and environmental footprint of flexographic printing as a whole. There is no need to wait; and flexographic printing will gain more recognition as the environmentally sustainable printing technology of choice.

The relief depth reduction may vary slightly depending on the washout solvent or plate material used, but it will always show a significant impact of the advantages explained. The benefits of environmental improvements are primarily seen in the hydrocarbon washout solvent process, but this process can likewise be used in water-wash or other platemaking technologies too. Whether to use 0,2 mm, 0,3 mm or 0,4 mm, relief depth should be decided by each customer, but it is no longer reasonable for a relief depth of 0,6 mm for 1,14 mm plates to be classified as a standard from a technical point of view. This is especially true today that, as we consider the changing environmental climate, we all examine our platemaking processes to make as much of a contribution as possible to reduce our carbon footprints.

Taking this approach over time, it dramatically adds up savings of washout solvent and reduction of drying energy costs and plate production time. By extension, it reduces our industry carbon footprints, improving our climate impact and opening the chance for anyone to participate.

Dieter Niederstadt is the technical marketing manager at Asahi Photoproducts.

Pack4Good is a solutions-driven initiative helping the world’s largest fashion, food and beverage, and beauty and care brands eliminate Ancient and Endangered Forests from their packaging supply chains enroute to building a stable supply of low-carbon and circular alternatives.

“From the farmers in and around our vineyards to paper suppliers, packaging producers, and NGO partners, we are all united in our mission of creating an experience that marries beauty, function, luxury, and sustainability under our enduring motto: One quality, the finest,” said Iris Decamps Bret, Veuve Clicquot global head of product, Collections and Innovation. “We are proud to partner with Canopy on the Pack4Good initiative, and to bring the Ecoyellow gift box to our customers.”

“The Veuve Clicquot Ecoyellow checks all the boxes. It proves packaging can be beautiful, luxurious, on-brand, and sustainable,” said Nicole Rycroft, executive director of Canopy. “We are thrilled to have Veuve as part of Pack4Good and for them to lead the way for other brands in reimagining the future of luxury – one that doesn’t compromise on quality or the planet.”

This project marks the start of Phase II of the CPT, which aims to carry out or support projects to improve the recycling of all plastic packaging within the evolving Extended Producer Responsibility (EPR) landscape in Quebec and Canada.

Digimarc Recycle watermarks are applied within the package artwork without requiring special inks or print processes, and are visible to specialized sorting equipment, but imperceptible to consumers. The watermarks, when scanned by machine cameras, connect to a cloud-based database containing unlimited (and extensible) characteristics of the package, such as the manufacturer and specific product, prior use (food versus non-food), additives or the presence of components that are problematic for recycling. As such, it can help facilitate flexible packaging sortation.

“We are thrilled to launch such a forward-looking project and get our Phase II underway,” says the Circular Plastics Taskforce Steering Committee. “The results from our Phase I study show that even if flexible plastic packaging represents a significant portion of plastic packaging used in Quebec and Canada, their recovery rates remain low. One of the reasons is that today’s sortation equipment cannot distinguish between mono-material recyclable packaging and multi-material structures, therefore lowering bale quality. We believe Digimarc Recycle can help solve this challenge.”

“We are excited to bring Digimarc Recycle to North America and to help the Circular Plastic Taskforce achieve their circularity-driven objectives,” adds Emily Stolarcyk, sustainability program director for business development at Digimarc Corporation. “Digimarc’s digital watermarks, a key component of Digimarc Recycle, have proven to be a truly innovative way to correctly identify each unique package. Connecting watermarks to an extensible database of product and packaging attributes ensures we can help enable a more circular economy now and in the future. This will benefit facilities and brands in meeting their recycling goals, in both the increase of volume and the purity of recycled material.”

The first part of the project consists of testing the ability of specialized optical sorters to adequately capture flexible packaging with digital watermarks in a controlled environment. This test will be performed at the Pellenc ST R&D Center in Pertuis, France, with various flexible packaging samples manufactured by Balcan Innovations, TC Transcontinental (co-founder of CPT) and Winpak. Following the results of this initial test, the second part of the project, which should begin in 2023, will aim at testing this solution in a real-life environment and at a much larger scale, with the goal of producing film bales meeting the high-quality specifications of recyclers. To do so, specialized sorting equipment will be installed in sorting centres and recyclers in Quebec and Ontario to capture flexible packaging with digital watermarking put on the market by CPT’s retail and brand partners.

The project also seeks to confirm the effectiveness of Digimarc Recycle to provide traceability of packaging. Traceability is a prerequisite to produce food-grade recycled resin and will be key to comply with upcoming regulations that will be implemented to accelerate the transition to a circular economy for plastics.

That being said, the industry – across the entire supply chain from raw materials suppliers to manufacturers, brands and consumers – is shifting the way we think about packaging. In 2018, the EU passed Directive (EU) 2018/852 for packaging waste which states that by end of 2025, a total of 65 per cent of all packaging waste should be recycled. Consumers are beginning to demand less product packaging that is more sustainable yet can still adequately protect products. Brands are responding to these demands – and to their own sustainability goals – by turning to packaging converters for greener packaging options. And converters, in turn, are looking for ways to incorporate more sustainable materials and practices into their product development, manufacturing and distribution processes. The ultimate goal is to achieve sustainability across the supply chain. But achievement of this goal is not necessarily in line with corporate cost savings goals. In order to improve sustainability, investments must be made. And consumers need to be educated about the value of more sustainable product packaging and be willing to pay a premium for it.

Sustainability: A goal worth pursuing

Due to both consumer demand and climate crisis pressures, we see that sustainable efforts are becoming increasingly important to brands. To achieve a low carbon impact, brands must engage the entire supply chain for a life cycle assessment of the carbon footprint for each of their products. To the extent that other stakeholders across the supply chain have measured their carbon footprint in accordance with PAS 2050, the brands can actually apply those CO₂ emission calculations to their own footprint. Thus, brands should be looking for suppliers who are pursuing a carbon measured strategy or whose products/materials have already been measured.

Packaged versus fresh

There is another trend that is important to mention, and that is the growth of what is known as “Zero Waste Shops” selling unpacked food stuffs. While this approach is admirable in reducing packaging waste at a local level, it may not be able to solve the food waste problem on a larger scale. Food waste is a significant problem globally, and in many areas of the world, food security is a growing issue. Packaged food, on the other hand, especially if packaging material can be reused as a new raw material in a closed loop circular economy, can actually be more sustainable. Using lightweight functional barrier films in packaging to prevent moisture, oxygen and contaminants from food contact can vastly improve food shelf life and reduce food waste. In the end, non-packaged food on a large scale likely results in more spoiled food, actually wasting this valuable resource. Not everything needs to be packaged, of course. But there is value in a smart hybrid model for retail food that can minimize waste and maximize sustainability.

A final note

For flexographic operations, in addition to careful supply chain management, efforts toward carbon neutrality, and other sustainability initiatives, we see three growing trends that can help these operations be not only more sustainable, but also more profitable in 2022 and beyond. These include:

• More automated platemaking which reduces time, cost and carbon footprint in the value chain.
• In-house platemaking at the converter site. As more automation is introduced into the platemaking process, it becomes easier and more efficient and sustainable to bring platemaking in-house. A side benefit is that plate production times can be reduced from days to hours.
• Transitioning away from a hydrocarbon-based solvent wash platemaking process to non-VOC based alternatives such as water-wash.

If the pandemic has taught us anything, it is that life is not as predictable as we may have thought. And it is absolutely clear that the world has truly changed, even beyond the threats posed by the Coronavirus. We must come together to address these challenges in a meaningful way.

In the past one to two years, there has been a marked increase in awareness regarding problems of greenhouse gases, plastic waste, food waste and other issues related to achieving harmony between the development of human society and the global environment. No one individual, company or government can single-handedly cure the climate crisis. It takes universal, global collaboration and co-operation to get the world to a point where climate deterioration is eased.

Dieter Niederstadt is technical marketing manager, Asahi Photoproducts.

The plant oil component offers:

• Quick drying, as no heat is required to fix or dry the ink. The oil penetrates porous substrates leaving the pigment near the surface. This reduces energy consumption and eliminates the need for the whole drying system.
• Odour-free with improved food compatibility, as no monomers are used.
• Biodegradable and supports deinking.
• Not water-based so no biocides are required to keep the ink usable.

The print heads are easier to clean and less likely to clog as ‘open time’ is much longer. This helps enhance jetting reliability, performance, and printhead life. Low ink consumption is also enabled as the same optical density is achievable using 50 per cent less ink.

Graham Kennedy, director-Industrial Printing, Graphic Communications, Ricoh Europe, says, “Brand owners and printer manufacturers are increasingly focused on reducing their environmental impact and applying sustainable practices wherever possible. With our new plant-based ink they can seamlessly introduce positive changes that make a big difference without impacting their high quality printed results.”

Here are five approaches and concepts based on sustainability that can be applied when assessing a large-format printer.

Avoid pollutants
The ink and curing system determines whether more or less emissions occur. When selecting the inks, it pays to avoid solvent-based systems. This eliminates the need for ventilation systems that entail additional investment and operating costs. Emissions can be kept to defined limits by using low-pollutant or certified inks, such as Greenguard. In return, this opens up a wide range of applications because the print products can also be used in sensitive environments.

Systems with LED lamps offer more advantages for UV printing than mercury vapour lamps, which have to be disposed of as hazardous waste because of their composition. They also have shorter service lives than LED lamps, so operating costs are higher.

Use energy efficiently
Large-format printers are operated with electricity, and electricity should be used as efficiently as possible. ISO 20690:2018 sets standards here. The energy balance of systems that use heat for curing is relatively poor. The example of UV printing shows that LED systems also perform very well here as their power demand is low and they give off almost no heat. Room air-conditioning and heat-sensitive media are the keywords. Another factor is that – unlike mercury vapour lamps – LED lamps do not have a warm-up phase and they are only switched on when they are used for curing.

As well as drive systems, computers and monitors, significant power consumers also include vacuum pumps. They are used to hold the media down securely in flatbed and hybrid printing. Their consumption is high when they are running continuously at high speed. Underpressure-controlled vacuum systems reduce their speed as soon as the required underpressure has been reached. As well as saving energy, this feature minimizes noise pollution.

Use machines with long service lives
Manufacturing a printer leaves an ecological footprint behind due to the materials built into the machine and the energy used for transport and production. All these activities generate emissions. The longer the machine is operated, the more this impact will be offset. The same applies to investment costs.

Opt for low-maintenance equipment
CO2 emissions are also influenced by the frequency of service calls and consumable parts that need replacing. Reliable, low-maintenance machines keep emissions down because travel, transport and the consumption of resources are minimized. This has a side effect in terms of business management as users can plan and calculate downtimes and costs.

Claim subsidies
The examples given above show that a sustainable strategy boosts profitability. Moreover, many governments now subsidize environment-friendly solutions. Germany, for example, offers support for energy-efficient printing systems at Federal State level. The process may involve some effort on research and paperwork, but it will bring a fair amount of the investment costs rolling back into the coffers.

When purchasing a new large-format printer, it therefore pays to give consideration to the sustainability aspect – at multiple levels. Last but not least, an active contribution to environmental protection is also an image factor that can then be marketed.

In the fourth and final episode, Nithya Caleb, editor of PrintAction, speaks to Ward Griffin, president and CEO of Lowe-Martin.

Lowe-Martin was the first Canadian printing company to become EcoLogo certified in offset and digital imaging. In 2003, it was one of the first printing companies to earn an FSC certification. In 2011, it became the first carbon-neutral printer in Ontario.

Lowe-Martin is continuing to move toward its goal of becoming a digital, zero-waste production platform. We at PrintAction are delighted to recognize Lowe-Martin as the Most Environmentally Progressive Company of 2021.

Listen to the episode below!

This podcast series is also available on Apple Podcasts, Spotify, Google Podcasts or any other podcast app that you use.

As part of its sustainability strategy, Sun Chemical organized a Corporate Sustainability Committee in August 2020 comprising eight executive leaders, designed to guarantee company-wide engagement in sustainability initiatives and oversee the sustainability strategy. Under this committee, Sun Chemical has built a framework to guide future roadmaps in each of the strategy’s three pillars, which are referred to as the ‘five Rs’: Reuse, Reduce, Renew, Recycle and Redesign.

This framework supports a circular economy and reductions in carbon footprint, which can be applied from either an operational or product-oriented point of view. Each of these steps has enabled the company to align its sustainability goals with the United Nations’ Sustainable Development Goals.

The latest report shows Sun Chemical achieved its recent energy and water usage goals and outlines ambitious new initiatives that align with the three key pillars strategy and ‘five Rs’ approach.

“The sustainability report shows Sun Chemical’s commitment to our sustainability goals, but we’re continuing to find new ways to improve,” said Michael Simoni, global product stewardship leader, Sun Chemical. “By guiding future product development based on reuse, reduce, renew, recycle and redesign, Sun Chemical is able to develop the next generation of industry-leading, high-quality products that further increase the use of bio-renewable and recyclable materials for our customers.”

The Sun Chemical sustainability report is available to customers and can be requested online.

President and CEO of Prime Data, Steve Falk says, “I don’t think I’m alone when I say that I’m having trouble taking action on climate change because I don’t understand how my life and work really affect it. I commissioned this study and had it focus on the core work we do, which is a simple letter with a reply envelope inside an envelope, often used by charitable organizations to fundraise. We produce millions of these each year and I thought that many of these organizations would also be curious about the outcomes of the study.”

The sustainability study, commissioned by Prime Data, found that a typical direct mail piece weighing 20 gm generates an average greenhouse gas footprint of 205 gm. To put this in perspective, a half-cent would pay for offset credits to make this mail piece carbon neutral.

The journey of a direct mail piece, produced and mailed in Canada by Prime Data, can be divided into three sections: Paper production, Prime Data production activities and Canada Post delivery. In Prime Data’s sustainability study, paper accounted for 85.5 per cent of the greenhouse gas footprint per mail piece sent by Prime Data, followed by Canada Post delivery at 10.5 per cent and Prime Data production activities at four per cent. For this reason, the greatest impact can be had by making informed decisions around the type of paper used for direct mail.

The Prime Data operations footprint mainly consists of electricity (4.3 per cent), delivery (20.2 per cent), employee commute (24.3 per cent), and natural gas heat for the facility (51.2 per cent). Some immediate actions that Prime Data is looking at to further reduce their carbon footprint in the direct mail industry are:

• paper selection – encourage customers to review paper options;
• energy efficiency in the warehouse – LED lighting installation, implementing dock door seals and air curtains;
• commute times for employees – working online has reduced emissions from employee commutes, and using a hybrid work model moving forward; and
• offset credits – exploring options to offset emissions.

Falk is an active member of the Sustainable Mail Group, a community of mail industry participants with similar interests. Their mission is to be stewards of the environment, working within the direct mail industry to offer continuous thought leadership and sustainable solutions that meet consumer demand for responsible mail.

“Our research is not the final word but an opening of the conversation, offering perspective into the various sources of greenhouse gases in the direct mail business. We hope to inspire dialogue on this subject and enhance our collective understanding of these issues,” says Falk.

Download a copy of the study here.

SMG has 90 members including Canada Post, Lowe-Martin, Direct Response Media Group (DRMG), Domtar, Marketing Kitchen and other companies involved in the production and distribution of printed mail. Ward Griffin, CEO, Lowe-Martin, is SMG’s board chair. Stéphane Dagenais, region manager, Canada–Printing & Publishing Papers, Domtar is the vice-chair. Jennifer Davey, account director at Marketing Kitchen is the board treasurer/secretary. Jennifer Bradbury, president & COO at DRMG, Eleanor Rafter, director of partnership strategy and relationship at Canada Post, and Richard Kouwenhoven, president and COO of Hemlock Printers, round out the SMG board.

Steve Falk, president of Prime Data, is the chair of SMG’s communications committee. I spoke to him about the goals of the new group as well as the potential of direct mail.

Steve Falk

Pressing issues

SMG was created to start a discussion and inspire research and action to address sustainability questions in the printing industry, as the lasting effects of global warming are becoming increasingly apparent.

“When coming out of the pandemic, we want to at least responsibly look at ways of reporting on how the industry creates greenhouse gas emissions, addresses its environmental impact and offer some creative, responsible and balanced solutions,” said Falk.

Further, the print industry has to deal with the damage caused by pandemic-induced economic shutdowns as well as find ways to stop the steady decline in the commercial printing sector.

“This group is trying to not only recover from a drop in overall print use, which is quite substantial, but also trying to comeback with some best practices for printing sustainably,” explained Falk.

SMG is also seeking to revitalize the industry, and bring talented individuals and companies together in order to reimagine the Canadian printing industry, especially the production of direct mail.

Photo © Enrique Del Barrio/ Adobe Stock

Direct mail

Direct mail is an effective marketing tool. According to statistics by Canada Post, direct mail has a 20 per cent higher motivation response than digital media. Consumers pay 39 per cent more attention to campaigns that integrate direct and digital mail than single-medium campaigns.

“There are people who know that direct mail works. Real estate agents, home service providers, restaurants and fast food chains continue to use it because it’s a great way to get in front of people with regular tear-off coupons that are good for a limited time period. It motivates people to come back,” said Falk.

Direct mail helps create reoccurring customers, as it enables brands to ‘remind’ customers about their services and products.

Nevertheless, direct mail is often overlooked by marketers. As Falk explains, the cost of direct mail, new digital channels and a hard-to-understand ROI are hindering the industry’s growth.

“Advertisers have diverse channels to choose from for their marketing campaigns. Print is one of the more expensive forms. Print campaigns take longer to implement and the results are not always available immediately,” said Falk. “Therefore, it’s been challenging to justify print budgets when marketing to advertisers.”

The printing system

On the bright side, technology is enabling printers to personalize direct mail, which makes it more appealing for targeted advertisement campaigns. In his company, Falk uses the Delphax Elan sheet-fed, colour inkjet press.

“We are able to hyper-personalize neighbourhood mailings. Instead of the whole country getting one flyer, we could alternate offers. It basically transfers the best of digital advertisements onto the print medium,” Falk said.

This flexibility allows for direct mail to be catered to specific individuals. As Falk explained, the inkjet technology has brought flexibility into what was mostly a stagnate medium. “With inkjet technology, you can basically on-the-fly variable print just the right amount of mail for each town,” said Falk.

He revealed that some recent campaigns did find success in markets that printing typically doesn’t touch. “We are seeing success with marketers who aren’t traditional mail users,” said Falk. For instance, e-commerce companies that typically promote directly to customers with digital channels are now adopting direct mail effectively. Also, some B2B marketers find print an effective way to boost e-mail and phone marketing now that e-mail is so overcrowded and universally filtered.

Plans for SMG

SMG’s immediate focus is on expanding membership. “We are looking for an expanded group that would include more mail users, such as bankers and marketing professionals,” said Falk. If you want to join the group, visit www.sustainablemailgroup.ca, and hit the “Join SMG” link. You can also get more information and regular updates on sustainability issues by joining the Sustainable Mail Group on LinkedIn.

This article originally appeared in the October 2021 issue of PrintAction.

This rating puts Jones, a provider of advanced packaging and medication dispensing solutions, in the top 20 per cent of best companies rated by EcoVadis in 2021.

EcoVadis provides a comprehensive evaluation for companies in the areas of environment, labour and human rights, ethics and sustainable procurement. The EcoVadis platform has rated over 75,000 companies worldwide in 160 countries.

“The healthcare industry has set some really ambitious goals around sustainability and we, as a specialist healthcare packaging company, have an important part to play in delivering them,” says Nic Hunt, chief strategy officer at Jones. “As an evidence-based assessment, the EcoVadis silver-medal rating means our sustainability approach is supported by policies, actions and outcomes that demonstrate our commitment and progress.”

“We focus on three key areas where we can make the greatest impact on sustainability: minimizing our consumption to reduce carbon footprints, maximizing circular design in our products and services to support a circular economy and creating an ethical, diverse and inclusive organization where people thrive,” adds Ron Harris, Jones president & CEO. “We’re proud to receive this important designation from EcoVadis – a sustainable future matters to us, our business and our clients.”

Back in 2018, Gecko Green Line Premium was the world’s first flexographic and gravure ink series to receive the C2C Certified Material Health Certificate at the Silver level. Since then, the ink specialist has continued to push the issue of sustainability within the company and has now achieved full certification at Bronze level for the ink series. As part of this certification, the Cradle to Cradle Products Innovation Institute does not only evaluate environmental and human toxicity (“material health”), but also the categories of recyclability/circularity, use of renewable energy and carbon management, responsible water management and compliance with social standards.

Dr Lars Hancke, business development manager, Flexible Packaging at Hubergroup, said, “We look at sustainability holistically. After receiving the C2C Certified Material Health certificate, the logical next step for us was to organize our actions and processes even more sustainably. The Cradle to Cradle Certified Products Program was exactly the right approach for us, as it is very comprehensive and rigorous.”

“C2C presents a well-accepted and scientifically proven method to validate the characteristics of sustainable materials, products and systems by putting a major role on the human and ecological health impact of the chemical substances used as constituents. With C2C brand owners have the opportunity to demonstrate their innovation efforts to keep their sustainability promise,” says Dr. Stefan Häp, head of technology and innovation brand owner collaboration at Siegwerk. For the development of the sustainable stand-up pouch, the developers followed a plan set up by the accredited institute, EPEA Switzerland, to comply with the Cradle-to-Cradle principle.

For the product to be wholly circular, the ultimate award requires adjusting screws at every part of the value chain.

“The development of the pouch shows that sustainable products cannot be rushed. They need time, investment, innovation and close co-operation among all partners along the entire value chain if they are to be truly recyclable in the end,” emphasizes Immo Sander, head of packaging development at Werner & Mertz.

Siegwerk developed the ink technologies for several applications and substrates. “We took care of the initial ignition for the sustainable inks on self-adhesive labels and on films for pouches,” says Dr. Häp. For this purpose, Siegwerk developed special ink systems that fit into the certified environmentally friendly concept and the sustainability strategy of Werner & Mertz.

Using different chemistries, the Evolution Deinking Primer and the Evolution Caustic Resistant Overprint Varnish (OPV) are designed to increase the yield of material in the recycling process. Both coatings have been recognized by the Association of Plastic Recyclers to comply with the guidance for PET packaging.

The Evolution Deinking Primer is used on shrink sleeve materials that makes the ink release in the caustic bath of the recycling process. When used with crystallizable polyester shrink sleeve material (CPET), the primer keeps the ink anchored to the substrate through the usable life of the sleeve, but releases it in the caustic bath. The ink is removed from the sleeve material without contaminating the valuable bottle flake. The materials are then rinsed and pelletized into recycled polyester (rPET) for reuse.

The Evolution Caustic Resistant OPV is a UV-flexo overprint varnish to facilitate recycling PET bottles utilizing pressure-sensitive labels. The varnish minimizes contamination of the wash water and bottle flake in the caustic bath by keeping the ink secured to the label substrate. When immersed in the float-sink bath, the label is released from the bottle and floats to the surface where it is separated from the bottle recycling stream.

Neither the Deinking Primer nor the Caustic Resistant OPV has any impact on ink colour, image quality or code readability.

John Pogatschnik, North America marketing manager, Flint Group Narrow Web, said, “The Deinking Primer and Caustic Resistant OPV are simple to use and offer optimal performance at all stages of the label or sleeve life cycle, while meeting the stringent requirements of the APR critical guidance. Switching to these new products is disruption-free, has no adverse effect on functionality and works with our standard inks.”

As part of the anniversary celebrations, PrintAction has created a podcast series focusing on some of the important developments in the industry.

In the third episode of the series, Nithya Caleb, editor of PrintAction, spoke to Richard Kowenhoven, president and COO of Hemlock Printers, and Amanda Chor, sustainability manager at Hemlock Printers, about the print industry’s role in Canada’s fight against climate change as well as the importance of adopting sustainable business practices. Click here to read the blog mentioned by Kowenhoven in this episode.

Listen to the episode below!

This podcast series is also available on Apple Podcasts, Spotify, Google Podcasts or any other podcast app that you use.

After scoring Envirofoil 19 out of 20 total points for recyclability using methodology developed by the bifa Environmental Institute, Interseroh, in Cologne, Germany, authorized the use of the “Made for Recycling” quality seal for packaging made with silver or holographic Envirofoil. The Lucense Research Institute, based in Italy, granted Envirofoil the certification “Recyclable with Paper – Aticelca 501.”

Hazen president John Hazen said, “These environmental seals of approval telegraph quickly to consumers that the products they are buying are packaged sustainably. The ability to verify sustainability is increasingly important to consumers, so it is also important to brand owners, and to us.”

Envirofoil is manufactured with less than one per cent of the aluminum of traditional foil laminate or film laminates, reuses the film carrier multiple times, and is recyclable as paper, as attested by these new certifications.

ZenCode solvent-based inks were designed with the environment in mind and to promote the development of a circular economy in flexible packaging. Specific coloured inks, whites and a range of one-component and two-component overprint varnishes are available for both flexographic and rotogravure printing – including expanded colour gamut printing – and incorporate a certified range of chemistries.

The Cradle to Cradle Products Innovation Institute is a non-profit organization created to bring about a large-scale transformation in the way items are manufactured. Its mission is to provide a continuous improvement quality standard to guide product manufacturers and designers in making safe and healthy products.

Thomas Strohe, senior director of product strategy and segmentation for Flint Group Packaging Inks in Europe, said, “We were delighted with the outcome of the ZenCode assessment. It reflects our commitment as an organization to continuous improvement in product design and development. We are continuing to have a number of our products assessed to ensure we are meeting our sustainability vision of supporting packaging markets with responsibly built products and sustainable solutions designed for circular economies.”

The Cradle to Cradle Certified Material Health Assessment methodology is a contextual assessment based on chemical hazard identification and qualitative exposure considerations during a product’s final manufacture, use and end-of-life.

The assessment concluded that all materials used in the ZenCode range were either optimal or acceptable for use as defined by the Cradle to Cradle Innovation Institute and do not contain any highly problematic materials. The product’s assessed materials are therefore confirmed to not contain chemicals on the banned lists of chemicals above permitted thresholds nor contain carcinogens, mutagens or reproductive toxicants. The range also meets volatile organic compound (VOC) emissions testing requirements, as described in the Standard.

Coca-Cola HBC’s larger multipacks (10, 12, 20 and 24 cans) are now available in a new fully enclosed carton. This follows the introduction of Graphic Packaging’s new KeelClip late last year, which saw smaller multipacks (four, six and eight cans) transition to an innovative paperboard solution. Both packaging types were designed and developed by Graphic Packaging; in total, transitioning to these new secondary packaging solutions will eliminate 500 tonnes annually of hard-to-recycle shrink wrap plastic.

Coca-Cola HBC have also introduced prominent on-pack messaging to communicate their sustainability message directly to consumers, highlighting the packs are recyclable. The more premium feel of the pack will enhance the brand and elevate shelf appeal within the multipack aisle, improving point of sale and the consumer experience.

The product development team at Graphic Packaging worked closely with Coca-Cola HBC to ensure the plastic replacement solution was in harmony with the company’s sustainability plans, while upholding high quality standards. The design is made from paperboard – a substrate made from renewable resources – and reflects Coca-Cola HBC’s ambitions to lead in sustainable packaging design and innovation.

To support the production requirements of the venture, Graphic Packaging has installed the highly flexible QuikFlex machine in Coca-Cola HBC’s plant in Lisburn, Northern Ireland, producing a variety of configurations from four- to 24-packs.

Using the right sustainable tools
Sourcing sustainable paper isn’t as simple as one assumes. Certification, industry standards, government regulations and logos complicate a brand’s procurement policy. These brands need to peel back the onion and go to the source to deliver a truly sustainable choice.

Actionable data provides assessment for on the ground response
By using Canadian space tech company MDA’s RADARSAT-2 satellite-based forest alert service (FAS), the author’s company, Asia Pulp & Paper (APP), is able to capture forest disturbances down to a few trees. This allows APP to monitor, in near-real-time, and react to forest cover change resulting from natural causes, illegal logging or encroachment.

Every 24 days, satellite data is assessed for changes against historical imagery. Based on information, the APP team can assess, respond and implement necessary and targeted measures to reduce threats to its supplier plantations and address the environmental risks associated with illegal forest clearance.

What does this mean for paper buyers?
To address the growing demand for supply chain transparency, APP is making this data available on its public sustainability dashboard. Paper buyers now have full access into their sourcing partners and the assurances they need to deliver sustainable paper and packaging solutions. Further, retail brands can use the dashboard as a marketing tool to drive customers’ loyalty, targeting environmental minded consumer, as it can showcase sourcing locations and its environmental impacts.

What’s next
Real-time information will help validate transparency at a deeper level, and drive the urgency to protect natural forests while providing a comprehensive supply chain model shift within the paper sector.

Ian Lifshitz is vice-president of sustainability and stakeholder relations for the Americas, Asia Pulp & Paper. 

Every two years, PPEC surveys Canadian paper mills about their paper packaging import and export shipments, to determine the average recycled content used to make paper-based packaging products in Canada.

The average recycled content of domestic Canadian shipments of the three major packaging grades –
containerboard (used to make corrugated boxes), boxboard (used to make boxboard cartons), and kraft paper (used to make paper bags) – is 81.7 per cent according to the 2020 survey, up from 73.5 per cent in 2018. The average has steadily increased from 47 per cent in 1990, when PPEC first started collecting recycled content data from Canadian paper mills.

“PPEC is proud that the average recycled content of paper-based packaging products continues to increase in Canada,” said Chris Bartlett, chair of PPEC’s board. “Recycled content is a key component of a circular economy, as it keeps raw materials flowing longer, reducing the need to extract virgin materials.”

“Recycling plays a critical role in the environmental sustainability of the Canadian paper packaging industry,” added Rachel Kagan, PPEC’s executive director. “Canadians actively recycle their paper-based packaging, which allows paper mills to continue to maintain high levels of recycled content in Canadian made paper packaging.”

Key findings from 2020 PPEC Recycled Content Survey are:
• Total Canadian paper mill shipments: 3.37 million tonnes
• Total recycled content shipments to domestic and export markets: 2.35 million tonnes
• Average recycled content of domestic shipments for all three major packaging grades: 81.7 per cent
• Average recycled content for domestic shipments of boxboard, which is used to make cereal or shoe
boxes: 79.8 per cent.
• Average recycled content for domestic shipments of containerboard, which is used to make corrugated
shipping boxes: 86.5 per cent.

Plastic shipping containers have been replaced with cardboard and bubble-wrap with card-wrap as part of the organization’s ongoing commitment to cut their carbon footprint and tackle plastic pollution.

The ban on plastic packaging is the latest eco-friendly move by the Arden Group. In 2020, it became an ISO 14001 certified company. ISO is an international standard, which recognizes organizations that have a successful environmental management system in place.

Sarah Poynter, operations manager at Arden Engraving, said, “Every year, 12 million tonnes of plastic is swept into the ocean and packaging makes up for almost half of all plastic-use in the U.K. Everyone has a part to play in doing their bit to protect the environment, and here at Arden we’re part of the supply chain for sustainable packaging anyway, creating the tooling for the carton and paper-based packaging sector, so it’s a natural next step for us to ban plastic within our own external packaging.”

Deinking is the removal process of printing ink from recovered paper during recycling. Key process steps for deinking are the detachment of ink film from the paper, ink fragmentation into a suitable size range and removal from the pulp slurry.

“With this certification, our customers can be confident in running the widest range of substrates in the industry while being good stewards of the environment,” said Mario Mottillo, president, Konica Minolta Business Solutions (Canada). “Our unique VOC-free AccurioJet KM1e UV ink formulation coupled with complete deinkability allows us to help our clients create value for their customers and the environment.”

Konica Minolta’s AccurioJet KM-1e LED UV Inkjet Press already has the INGEDE deinking certification for coated papers, which includes recycled qualities. After rigorous testing and evaluation of uncoated papers by INGEDE, in which the KM-1e press achieved a high rating in the “Assessment of Print Product Recyclability – Deinkability Test” (INGEDE Method 11), the accreditation has been extended.

In 2020, a group comprising sector leaders related to the production and distribution of printed mail began building an organization where industry sustainability could be discussed, researched and better understood. They saw this as an opportunity to make a difference by addressing their environmental impact. Early members of the group represent the entire mail ecosystem and include Canada Post, printers, paper and envelope manufacturers, lettershop services, marketers and data services.

Mail continues to provide a stable and valuable communications channel within the rapidly changing digital ecosystem. The group believes there is a need to address consumer demand for responsible mail production practices. With tens of thousands of jobs involved and over 6.3 billion pieces of mail printed, produced and delivered in Canada each year, SMG invites interested parties from the sector to join them in fostering a better understanding of the environmental impact of their industry with the goal of adopting best practices.

For more information contact Steve Falk, chair of the communications committee at sfalk@primedata.ca.

• Expand their commitment to not source from Ancient and Endangered Forests as it applies to packaging as well as paper;
• Support conservation on the ground in Landscapes of Hope; and
• Participate in Canopy’s International Day of Forests awareness-raising campaign by educating and engaging their own clientele and supporters.

To illustrate that this update is slightly different, Canopy is not using their usual colour-coded ink drops to indicate how a printer has ranked. Instead, ink drops are used to represent recent actions taken for leadership on sustainability and forest conservation, which continue to build on the positions earned in the 2019 Blueline Ranking.

Printers with the most ink drops took action to improve their current sourcing while increasing the amount of recycled or next-gen content in their paper and packaging.

“In the coming months and years, solutions such as using agricultural residue or other waste streams to make pulp for paper will become increasingly necessary to save forests at the scale we need to prevent climate change and halt the cascading loss of species. What’s more, the 750+ brands that Canopy collaborates with to improve their sourcing are demanding it,” said an update from Canopy.

“UniNature is our third generation of sustainable water-based inks and coatings for paper and board applications meeting the requirements of brand owners and packaging converters,” says Hanns Martin Kaiser, vice-president, Business Units Paper & Board EMEA and Liquid Food Packaging at Siegwerk. “With its launch we again deliver on our commitment to enabling the development of new packaging innovations in line with a circular economy.”

The new water-based ink and coating solutions are formulated with a high bio-renewable content, measured according to ASTM 6866.

The new ink and coating series is applicable for many paper and board applications including corrugated board boxes, trays and displays, fast food packaging, sacks and bags, as well as cups and wraps. It supports various printing applications whilst meeting the highest market and regulatory standards.

Designed for use with Siegwerk’s Unibase and Uni T coloured bases, UniNature inks can be supplied as ready-to-use inks directly from Siegwerk. However, UniNature extenders and Unibase or Uni T colourbases are more frequently supplied to customers to be mixed on demand at dispense equipment directly at the customer.

“We provide our customers with clear formulation guidelines compliant with relevant regulations for the end use of the packaging,” adds Paul Pain, head of water-based technology at Siegwerk. “Training and support provided to customers through our OPS program enables the most efficient use of our products in their operations.”

Depending on the design, this technology can reduce label waste by reducing the decoration thickness to about a third of a typical clear pressure sensitive label and eliminating label media plastic in non-print areas.

“Brands are taking a leadership position on sustainable packaging solutions, with ambitious waste reduction goals and a drive to increase the efficiency and scale of container recyclability,” explains Anthony Carignano, technical director marketing – Signite, Actega. “At the same time, these companies are seeking ways to unlock new high-quality label aesthetics and tactile experiences for premium products. Signite offers these brands the best possible chance to meet all of these objectives.”

Signite promises to be a pioneering solution for numerous market sectors and aims in the future to support the high-volume production required by high-profile brands. Today, the solution is ideal for small volume contract decorators and specialty brand owners looking for a substantial differentiator that strengthens their competitive edge.

SGP is the only certification organization promoting sustainability in all printing processes throughout the United States and Canada.

CWSC aims to align the packaging industry to follow a science-based route of all waste to syngas to “green methanol” for the production of virgin packaging materials. This ends the practice of landfills and incineration.

SGP resource partners are nonprofits, NGO’s and educational institutions engaged in promoting, teaching or researching in the areas of graphic arts and/or sustainability. Resource partners are subject matter experts that assure the entire community is empowered with the acumen to advance sustainability in the printing industry supply chain.

“SGP’s focus on streamlining resource consumption during printing manufacturing to be sustainable and environmentally friendly goes hand in hand with the end of life focus at CWSC to create an endless loop of circularity,” said Mike Ferrari, president, CWSC.

“CWSC promotes an innovative technology to treat waste and convert it to feedstock for virgin materials. The leadership teams of CWSC and SGP are excited to work together to make progress on sustainability challenges the printing industry faces,” said Doreen Monteleone, SGP treasurer and Flexographic Technical Association representative.

Digital printing is here to stay. The digitalization of printing is a major step toward reshaping the whole converting industry. The main print-press vendors are quite advanced on their digital roadmaps even as new players enter the scene. Though lively, the digital printing industry is fragmented. A phase of business and market consolidation can be expected in the coming years, driven by the need to adapt to new technology needs or uses. We are also witnessing a strong surge in print-in-production, with history seemingly repeating itself, as ‘printing’ comes back to ‘production’.

Each print output is potentially unique with its own variable data that can be managed flexibly by creating an agile printing process.

As our printing journey advances, technologies mature and prices fall, we will always find new opportunities to leverage the benefits of digital printing. However, we will also be confronted by new regulatory requirements and different kinds of barriers. Currently, two factors are critical for the efficient adoption of digital printing.

Sustainability

The first aspect relates to eco-friendly print production. Nestlé has committed to using only recyclable or reusable packaging by 2025. To help meet this commitment, the company established the Nestlé Institute of Packaging Sciences to explore alternative packaging materials along with suppliers and other external partners. We can already anticipate that these materials, such as paper-based laminates, have lighter barrier properties compared with materials in use today. This presents a challenge to the related printing processes that will constrain their use. Of course, digital printing inks have made huge progress in food-compliance and are still improving. However, on new packaging materials with lighter barrier properties, some printing systems (the combination of a printing process, an ink and its finishing process) must be adapted to meet strict food packaging requirements. Additional goals, such as reusability and recyclability, should also be considered. Are today’s ink formulations, developments and finishing processes ready for this transition?

Data management

PHOTO: © DMYTO / ADOBE STOCK

The second aspect underlying the promise of digital printing has to do with variability in the printout (output) as well as flexibility in the printing (process). Print jobs are increasingly related to data management, as each output is potentially unique with its own variable data that is managed flexibly within an agile printing process.

Late-stage customization is the ability to customize the output at the latest stage, which itself refers to moving printed packaging from a conventional rigid supply-chain to a networked supply-chain where multiple players can print different static and variable layers of an artwork in one or several locations. It means moving away from a monolithic approach where the full printing and converting processes are entirely outsourced to a situation where many supply-chain options are available to cover the high variety of products, business models and routes to market (from fully outsourced supply to fully internalized printing and converting, with mixed approaches in-between). This is our definition of variability and flexibility, derived from data-driven print production and late-stage customization.

To achieve all this, the dots need to be connected, meaning the print-job data as well as the printing and converting process must connect seamlessly into an integrated end-to-end supply-chain workflow. This integration and connectivity happen in two dimensions, namely horizontally and vertically. Horizontal integration involves the progressive digitalization of the complete converting machinery and processes, streamlining the repro while ensuring colour matching and consistency. This digitalization has already occurred for the artwork and prepress; is happening for the printing step; and will progressively include the decorating, cutting and folding-gluing steps as well as other converting steps. Vertical integration relates to the print and converting-data. It ensures the right output is achieved from the correct data in a make-to-order or print-to-order model. Both static as well as variable artwork data must be aggregated dynamically together with production-specific data coming from a production order, which, in the end, can make every pack literally unique, if required.

At first glance, this degree of integration and connectivity to achieve a batch-of-one might sound futuristic, and is definitely ambitious, but the reality is that all the necessary technology-related building-blocks already exist. Digital front-ends rip dynamic artwork for the printer. Manufacturing execution systems dispatch production order information to the various assets of a production line. Dedicated servers ensure additional functionality, such as serialization or aggregation. For each and every type of data, a dedicated and well-optimized channel exists. Additionally, connectivity standards are maturing and being adopted to ensure both horizontal and vertical communication between all the modules of a production environment. All these channels, which are mainly independent today, can start to be interconnected to combine, as and when needed, the relative data, rip it accordingly, and finally print it to produce unique packaging items.

Data is the fuel of today’s economies. The ability to create, collect, handle, combine, extract, analyze, process and convey data will drive the most efficient businesses. Printing is no longer about accurate colour-matching and process-efficiency. It is rather about conveying to buyers and consumers digital information that has been applied physically on the pack. Some call it the blended reality. Nonetheless, it is a paradigm shift enabled by combining digital printing with connectivity. Such a shift is a prerequisite for achieving personalization and customization, the “holy grail” of the digital transformation in consumer package goods (CPG). This paradigm shift can help one envision the connected production-floors and factories of the future.

Alvise Cavallari heads Nestlé’s corporate digital printing programme as well as other related activities.

This article was originally published as part of the Drupa Essentials of Print series and reproduced in the April 2021 issue of PrintAction. 

These adhesives are natural, biodegradable, recyclable and vegan friendly and are used in lieu of conventional glues made from animal byproducts. They are typically manufactured from potato starch, are water-based, use no solvents and are compliant with both European and U.S. food contact regulations.

“We decided to implement dextrine-based adhesives because they are in better alignment with new environmental trends, aiming for increased sustainability. Further, they are also in line with Swedbrand’s sustainability strategies,” said Facility manager Bogdan Putko.

Dextrine water-based adhesives function with a wide variety of machine types and processes, with the ability to produce up to 15 glued boxes per minute.

Member companies submit details about their sustainable business practices, operations instituted in reducing the company’s environmental footprint, improvements to employee safety and well-being, all while optimizing the company’s bottom line.

All applications are reviewed and recommended for award designation by PRINTING United Alliance’s Sustainability, Safety, Health and Personnel Advisory Council.

2021 Sustainable Business Recognition Award recipients

PRINTING United Alliance member companies awarded with this designation are as follows:

• Albert Basse Associates
• Bolger Vision Beyond Print
• ColorLogic GmbH
• Echo Communications
• Empire Screen Printing
• Lawson Screen and Digital Products
• LEM Products
• MegaPrint
• Night Owls
• Ricoh USA
• S-One Holdings Corporation
• Stratojet USA
• Surrey Digital Printing
• T-One Print PTY Ltd
• Vapor Apparel

“PRINTING United Alliance proudly serves as a leader in guiding our members on how to implement and navigate environmental, health, and safety initiatives and best practices in what can often be an ever-changing, confusing environment,” said Marci Kinter, vice-president, Government & Regulatory Affairs, PRINTING United Alliance. “Each year we greatly anticipate the different submissions we receive as there are so many programs out there that are truly making a difference. We are proud of these members who go above and beyond in implementing extraordinary measures in environmental sustainability and responsibility.”