Packaging and Environmental Compliance
By Tom Kerchiss, RK Print Coat Instruments
Product producers are under pressure to endeavour where possible to present and market food and beverage items and much else beside in packaging that has minimal impact on the environment. Consumers, environmentalists, pressure groups, politicians, the media – even the packaging technologists and those in the front line of producing a finished pack, the printers and converters are all aware that changes will need to be made.
Everyone would like the packaging material to be made either from sustainable resources or from new materials, especially those that rely less on fossil fuels. But of course; it doesn’t rest there; local authorities, those responsible for waste disposal and the environmentally aware would like to see a further reduction in the amount of waste going to landfill. Many believe that products often contain too much packaging. Few realise that often what is perceived as unnecessary packaging is generally in place as a means of protecting a product from moisture or the ingress of gases, to extend product shelf life, etc.
Packaging product developers, including those engaged in ink, coating and adhesive production face interesting times. Will they rise to the occasion?
It is interesting to see the circular nature of some aspects of processing and concern for the environment. For instance: prior to 1960 many plant oils such as linseed, soy, corn and even Canola were common ingredients in ink. However, advances in press manufacture, faster press speeds and the need for inks that dried quicker resulted in manufactures and processors switching to petroleum-based products.
Eventually, and it did take time, technologists in many fields realised that products distilled from petroleum and used as drying agents, solvents or cleaning solutions in various print processes were ozone depleting and responsible for the emission of volatile organic compounds,
Plant based materials once again came onto the scene with citrus and terpene-based materials often substituted for solvent -based agents. Although it has to be said there was and is no perfect solution for every processing issue that arises in printing, converting and packaging there are often compromises and work arounds; indirect or direct substitution and partial substitution.
On occasion, a plant shares the performance characteristics of a petrochemical formulated substance. For instance, the chemical phenol used in printing can be produced both from plants and from petroleum. When produced from plants, bio-phenol generates as much as 80 per cent less in way of hazardous emissions or pollutants than petroleum derived phenol.
Phenol is an example of partial substitution. As its name suggests is a product or component where some VOC and other hazardous substance is still generated but to a lesser degree than its petroleum derived counterpart.
Product/process substitution involves the complete replacement of a petroleum based or other chemical structure with a product perceived to be more environmentally friendly. Aqueous or water-based inks, coatings and adhesives fall within this category.
In the last few years packaging technologists, chemists and others have ramped up research and development in a number of areas. Bio-polymer materials derived from polysaccharides, proteins, lipids or a combination thereof are renewable and potentially may address many of the recyclable and compostable issues.
With regard to materials or formulae that share the same performance properties typically associated with conventional petroleum products and which are used in the production of food and beverage packaging prominent materials there are the Bio-PE and for bottles the Bio-PET materials.
Products that are good for semi-permeable applications, are compostable and provide various levels of barrier protection materials include cellulose and PLA.
Polylactic acid or PLA is one of the most commonly used bio-degradable polymers and can be used for some plastic food packaging applications. PLA is said to offers good clarity, good dead fold characteristics. It is compostable and is similar to PS in terms of stiffness.
Starch and cellulose related materials are widely used with research and development still taking place. The former, made from renewable sources such as potatoes and corn are subject to a number of try outs at the moment. For example, the online grocery retailer Ocado is using a bag made from synthesised potato for the distribution of their magazine.
Ocado is not alone, the WI Life, the magazine of the Woman’s Institute or WI is distributed wrapped in a potato starch bag. Once the bag is opened and the magazine is taken out the WI recommend that the bag be used to line a food caddy bin. When the bin is full up with food waste the bag and contents can be collected by local authority waste collectors. Alternatively, it can be composted at home.
There are so many products being developed that it would be impossible to mention them all. Many of the materials being developed are for coating purposes. For instance: Chitosan, a derivative of crustacean shells is being used as protective barrier coating for paperboard substrates. Carvacrol, a component of oregano and various essential oils are also the subject of investigation and are viewed for possible coating inclusion in specific segments of packaging where microbial growth needs to be excluded or at least contained for a long as possible.
Development of any product does not occur in isolation. Processing practicalities very quickly surface; will the new material readily convert? Is it easily printable? How will ink and substrate interact over time?
It takes time to ensure products perform seamlessly; product development devices, monitoring systems, those suited to undertaking trials, testing formulae and theories are invaluable. Ink manufacturers, chemists, coating professionals, additive and resin producers need to ensure compatibility, coating technologists and converters need to determine the most suitable and most economical coating technology to use.
When it comes to product development and conducting trials it’s useful to employ a monitoring system capable of undertaking small-scale production runs. RK Print Coat Instruments provide colour communication or pre-press proofing devices as well as bespoke coating systems such as the VCM. A game changing device, the VCML Lab/Pilot Coater is also now available.
The VCML-Lab/Pilot Coater enables operators to print, coat and laminate on all types of flexible substrates and on a reel-to-reel basis. The VCML Lab/Pilot Coater has the ability to apply various inks, varnishes, adhesives and paint using environmentally acceptable formulations and where necessary solvent-based materials as well. It offers short run production capability, making it ideal for speedily bringing products to market; for monitoring quality and for undertaking many types of tests and procedures.
The VCML Lab/Pilot Coater has a web width of up to 300 mm, is touch screen controlled and is equipped with a cantilevered unwind and rewind, head mounting station with tray lift and trough and a laminator station with pneumatic nip.
Flexography, offset gravure and gravure, knife over roll, reverse coating, meter bar, slot die and many other processing options can be made available. The VCML Lab/Pilot Coater can be configured for hot air drying, infrared, UV curing and for corona treatment. Edge guide and heated laminator and ATEX coating zone can also be integrated in with the system.
Finally, the VCM or Versatile Converting machine can be designed and configured for customers with specific needs operating across many industries. Very much a machine for 21st century requirements the VCM can be used for advanced packaging product and material development and for polymeric semiconductor, latent imaging, medical diagnostic, solar reflective film production and much more beside.
RK Print Coat Instruments Ltd
Litlington, Royston, Hertfordshire SG8 0QZ
www.rkprint.com sales@rkprint.com
Source: RK Print Coat Instruments Ltd
