FPT 2 2022

Case Study: The Secret to 14 Years of Continuous Cleaning Anilox Cell Geometries For Printable Electronics and Flexible Packaging

Can chemical recycling close the plastic loop?

Five pieces of the circular packaging puzzle

Geissmann Renews Its Confidence in Comexi with the Acquisition of a 10Color F2 MP

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The anilox was original engraved mechanically using a stylus to peck at the surface. This limited the size and profile of the engraved cells.

However, laser engraving has enabled much more control with a variety of shapes and aspect ratios.

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Reduce, reuse, recycle is all very well in theory, but when it comes to the latter, only certain types of plastic can be handled by existing mechanical processes. Could emerging technology such as feedstock recycling, chemical depolymerisation and solvent purification offer a solution?

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It’s no secret that the packaging industry is under ever-growing pressure to shift to a more sustainable future. The speed of this transition and the winners and losers within the industry are far from obvious, however. Pricing, legislation, brand commitments, chemical recycling and bottlenecks are five fundamental pieces of the sustainability puzzle.

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What is the secret to long-term success with a Flexo Wash cleaner?

For this company it was pairing the highest-quality cleaning system with a consistent preventative maintenance program and dedicated employees.

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The flexographic printing press will allow the Swiss company to further strengthen its leadership position in the highly competitive Swiss market

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Anilox Cell Geometries For Printable Electronics and Flexible Packaging Flexography is a major high-volume printing process used extensively for flexible packaging. The heart of flexographic press is the anilox roll, which meters the flow of ink to the image carrier (plate) by virtue of the engraved cells on the surface. The anilox was original engraved mechanically using a stylus to peck at the surface. This limited the size and profile of the engraved cells. However, laser engraving has enabled much more control with a variety of shapes and aspect ratios. Much has been claimed by the manufacturers for these new designs – improved ink transfer, higher volumes of ink transfer and better half tone reproduction – on the basis of industrial field trials.

The objective of the research reported in this thesis has been to quantify the ink release from the anilox to the plate for both traditional cell profiles and the open channel designs.Previously, the ink release was mostly determined by examining the optical density of the print products. The optical density is a qualitative indicator of the ink release from

anilox cells. These studies were limited to closed anilox cells with a low ink viscosity, as typically used for graphic prints.

This study explores an extended range of anilox cell shapes, including open channel geometries, and the ink viscosities. The ink released from the anilox cells has been be directly measuring and quantified experiments

were performed printing directly to glass and on flexible packaging at a commercial printers to establish the current industry position. A laboratory scale printability tester was then used to study ink release using three inks: UV Cyan, Carbon and Silver.

These represented a link to the graphic experiments in previous published studies, while the Carbon and Silver

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were highly viscoelastic functional inks used in printed electronics. Four cell geometries were used: laser engraved closed cells, extended hexagonal and wavy channels together with mechanically engraved conventional closed pyramid cells. The laser engraved anilox afforded the opportunity to vary key parameters of cell width, depth, profile and volume. A brief exploration of print speed was also undertaken with exemplar anilox of each cell type. The main study considered ink transfer to a 100% solid plate, as this would allow the ink release to be studied without influence of the plate distorting into the cells thereby extracting more ink. A limited study was then undertaken with a half tone plate to establish the impacted on ink transfer.The amount of in transferred was highly dependent on the absolute volume of cells, i.e. the amount of ink available on the anilox.

The anilox cells with wider, shallower and smaller depth-to-width ratio released a higher proportion of the ink.

The ink’s physical characteristics of viscoelasticity and extensional viscosity also determine the proportion of ink transferred.The anilox hexagonal closed cells (typically used in the flexographic printing process) performed best with the low viscosity ink. The information gaining from this study would aid in the design of anilox cell geometries and development of ink characteristics to enhance its capability for

functional print applications such as printable electronics. The anilox wavy channels released the greatest proportion of the ink with high viscosity, elastic modulus, and filament breakup time. The anilox wavy channel has the potential to be used for the functional print as it increased the release of paste-like ink. Additionally, it improved the ink lay-down. The anilox engraving technique affected the ink release.

The anilox cells, which were engraved by the laser technique, gave greater ink release comparing to the anilox

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cells, which were engraved by the mechanically engraving technique. The increase of the dot coverage increased the ink release out of the anilox cells because of the increase of the receiving area.

However, the increase of the ink release plateaued after the dot coverage of 50% for UV Silver because of its large filament breakup time.The characteristics of ink influenced the ink release out of the anilox cells. Unlike previous work which examined only the ink viscosity, this studied included ink elastic modulus and filament breakup. The ink with high viscosity and elastic modulus, but small filament breakup time gave greatest ink release for all anilox shapes. When the printing speed increased, it decreased the ink release due to two factors; reduction of engagement time between the anilox cells and the plate (reducing time for ink to transfer) and en-

largement of the filament extension rate (reducing the amount of ink transfer). The decrease of ink release was affected by the ink characteristics and the anilox cells shapes. The decrease of ink release was significant when UV Cyan ink (small viscosity and elastic modulus) was used with the anilox open cells and wavy channels. Contrarily, the decrease of ink release was insignificant when UV Carbon and Silver inks (large viscosity and elastic modulus) was used with the anilox open cells and wavy channels.The experimental data was analysed and the critical parameters in releasing the ink of the anilox cells were identified.

The depth of anilox cell was the most critical parameter; the shallower cell depth released a higher proportion of the ink. The ratio of depthto-width was the second most important parameter in determining the ink release. The smaller

depth-to-width ratio released more ink. The width of anilox cell could not be used as a parameter predicting the ink release because the wider anilox cell did not always release the higher proportion of the ink.

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Can chemical recycling close the plastic loop?

Plastic is being demonised – innovative circular processes could be its salvation Reduce, reuse, recycle is all very well in theory, but when it comes to the latter, only certain types of plastic can be handled by existing mechanical processes. Could emerging technology such as feedstock recycling, chemical depolymerisation and solvent purification offer a solution?

By Olivia Loa Research Analyst, Global Chemicals and Alexandra Tennant Senior Analyst, PET/RPET

Wood MacKenzie’s report Chemical recycling: breaking down the current landscape examines the potential for ‘plastic to plastic’ and ‘plastic to fuels’ chemical processes to pull significantly more material into the circular economy. Fill in the form to download a complimentary copy of the report, or read on for an introduction to the topic.

What’s the problem?

The issue of plastic waste may have cap-

tured the world’s attention recently, but plastics remain vital to the global economy. While global demand growth for plastic packaging is expected to slow down over the coming decades, the quantity of plastic waste created in 2040 will still be nearly double the amount today. Higher levels of recycling are therefore badly needed to avoid ever more plastic polluting the environment.

But traditional mechanical recycling, which breaks down plastic into small pellets but retains

a polymer’s natural structure, is only suitable for certain types of packaging and use cases.

What are the benefits of chemical recycling?

Chemical processes have the potential to capture over 50 million tonnes of plastic packaging waste currently considered ‘nonrecyclable’. Suitable material includes ‘other rigids’ (rigid packaging other than bottles), simple films and even

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complex films (film comprised of different layers of materials and/ or coatings). The potential to recycle a wider range of plastics can also incentivise overall collection rates for plastic waste.

What’s more, chemical recycling results in virgin-quality material that’s suitable for higher value end-use applications. It’s also more tolerant of low-quality waste and results in lower process loss due to its ability to process a diverse range of input material. Various big

brands support chemical recycling and are already collaborating with recyclers, including Coca-Cola, PepsiCo, Nestlé, Danone and Unilever.

ing blocks or monomers, in a process known as depolymerisation. Or it can be dissolved in a solvent to extract virgin-quality polymer.

Feedstock recycling is What use cases are already well-positioned there for chemically for commercial ramp-up recycled plastic? and offers a significant cost advantage. MeanChemical recycling can while, depolymerisation take several forms. shows the most promise Feedstock recycling in- in tackling the key chalvolves heating plastic lenge of providing foodwaste to produce hydro- grade recycled containcarbon products or syn- ers. Development of gas. Plastic waste can solvent purification is also be broken down currently lagging, but in chemically into its build- theory it provides the

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quickest and simplest path for plastic waste to re-enter the value chain at a higher quality than mechanical recycling.

getting access to sufficient raw materials in the form of bale feedstocks.

A gap between bale supply and demand has What are the chalexisted since China enlenges involved? acted its National Sword policy in 2018. This While chemical recycling banned the import of shows a lot of promise, most plastics headed for there are some obstathe country’s reprocles to widespread up- cessing facilities. Given take. One issue is that that China had previchemical recycling is ously handled nearly more carbon intensive half of the world’s recythan mechanical recyclable waste, the result cling. Yield may also has been an increase in struggle under commer- plastic ending up in cial operations. Howev- landfill, incinerators or er, one of the largest littering the environchallenges is simply ment.

How can the issues be overcome?

More widespread collection and improved infrastructure in the form of materials recovery facilities are badly needed.

Funding could potentially come from environmental legislation, such as extended producer responsibility (EPR) and plastic levies. Consistent regulation across geographies will also have a critical role in reducing the barriers to entry for chemical recycling and fostering stakeholder collaboration.

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Five pieces of the circular packaging puzzle Pricing, legislation, brand commitments, chemical recycling and bottlenecks will all influence long term circular packaging growth It’s no secret that the packaging industry is under ever-growing pressure to shift to a more sustainable future. The speed of this transition and the winners and losers within the industry are far from obvious, however. Pricing, legislation, brand commitments, chemical recycling and bottlenecks are five fundamental pieces of the sustainability puzzle.

By David Buckby, Senior Analyst, Films & Flexible Packaging In a recent insight by Wood Mackenzie, The circular packaging puzzle: five pieces shaping an uncertain picture, we consider how these factors will shape the future of the industry. Fill out the form for a complimentary copy, and read on for an introduction to some of the key themes.

Flexible packaging is a key piece of the circularity puzzle More than 75% of primary consumer packaging waste was not recy-

cled in 2020. Of this, almost 30%, or more than 19 MT, was mismanaged. This includes leakage into the environment, open burning and unsanitary landfill.

This is nearly six times the volume that went back into packaging through closed-loop recycling.

waste globally, its circularity is far worse than rigid packaging. In Europe, we estimate the recycling rates for flexibles and rigids at about 10% and 50%, respectively.

Household collection schemes for flexibles cover around two-thirds of the EU, but inadequate sorting ensures At the forefront of the that the quality and problem is primary flex- price of most recycled ible consumer packag- material is typically ing. Accounting for poor. The market, around 40% of primary therefore, provides little consumer packaging incentive for recyclers

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of flexible packaging and government interventions have been insufficient to change things.

Moreover, very little recycled content goes into flexible packaging. Due to food contact regulations, there is little to no mechanically recycled material in flexible food packaging. Many believe that the first step towards greater circularity in flexibles is ensuring that it is designed to be recycled.

This has led to a proliferation of interest in mono-material flexible packaging.

Barriers and enablers ready mono-material. of circular packaging The less good news is growth that we do not expect this share to grow More sustainable pack- meaningfully until the aging is more expen2030s. sive. Uptake is impeded As my colleague Andrew by ‘green premiums’, Brown wrote in Closing which typically arise be- the loop on plastic cause production costs packaging, creating a of more sustainable ma- circular plastic economy terials are higher. Legis- will take more than a lative reforms and ramp-up in mechanibrand commitments cal recycling. A successshould eventually reme- ful chemical recycling dy this; it’s a question industry, for instance, of when. should mean more recyThe good news for cir- cled content in packagcularity is that over ing overall and we may 60% of primary consee some shift from rigsumer flexible packag- id demand to flexibles. ing (PCFP) globally is al- While the technologies

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are still commercially nascent, 2020 and 2021 saw major new announcements of projects that will become operational pre-2025.

This investment feeds into a CAGR of more than 15% for chemically recycled plastic packaging up to 2040.

The biggest bottleneck to circular packaging, though, is the lack of collection, sorting and recycling infrastructure.

For flexible packaging, in particular, sorting is the biggest crunch point. Most waste sorting infrastructure is designed to sort rigid

packaging: flexibles can wrap around rotating sorting equipment and disrupt operations. Flexibles are typically seen as a contaminant and end up in landfill or incinerated.

streams based on their attributes. Industrial testing of this technology in Europe should conclude by Q3 2022.

Still, we expect circular packaging progress over the coming decades to vary markedly While existing sorting by region, polymer and technology is improving application. incrementally, a step change may be possible Mono-materials by adding digital water- growth marks to packaging.

The idea is that once Performance monopackaging reaches materials that can be waste sorting facilities, more easily recycled are these marks can be significantly more exscanned by cameras, pensive than incumbent enabling materials to be multi-material strucsorted into different tures. Legislation, de-

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sign guidelines and brand commitments to 100% recyclable packaging should accelerate uptake, but progress so far has been marginal.

The precise EU legal definition of a monomaterial (to be determined) will also affect uptake.

Mono-material uptake also suffers from bottlenecks in production.

Even if green premiums were lower, the capacity does not yet exist for barrier mono-material production to be rapidly ramped up. The requisite extrusion machinery is relatively scarce and will take years to install, especially with a limited number of machinery producers.

Packaging redesign time is another impediment.

For flexible food packaging, it typically takes around 18 months to develop and roll out a new design.

We currently expect mono-materials’ global share of flexible packaging to remain fairly steady in the 2020s.

However, it is easy to envisage a tipping point towards monomaterials: the upside case is highly plausible.

To find out more, fill in

the form at the top of the page for your complimentary copy of The circular packaging puzzle: five pieces shaping an uncertain picture.

This includes charts on: Mono materials global growth to 2050 Global chemical recycling growth Green premium ranges And more.

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Case Study: The Secret to 14 Years of Continuous Cleaning What is the secret to long-term success with a Flexo Wash cleaner? For this company it was pairing the highest-quality cleaning system with a consistent preventative maintenance program and dedicated employees.

Interprint (a Toppan company) operates in the decorative gravure marketplace where they develop and print designs used in the laminate decorative surface category for products such as flooring countertops, cabinetry, furniture and other like items. Their print surfaces uncannily resemble wood, marble, stone and granite, just to name a few. Interprint works with renowned designers to create some of the most popular decor surfaces.

In 2008, Interprint transitioned to in-house laser engraving of gravure cylinders to support their internal design development. This process uses zinc as the engraving medium. The zinc is galvanically plated directly over a copper base then laser engraved, cleaned, polished and a final layer of chrome is plated over the zinc to seal the porosity and provide a durable exterior for printing.

“gravitated toward the Flexo Wash system primarily for its minimal impact on the cylinder surface, meaning the system is less invasive to the cells (engraving structure) while cleaning compared to some other systems we have used in the past. In addition, we liked the fact we could use an environmentally safe low VOC cleaner to effectively clean the waterbased ink on our cylinders. We run a few different low VOC waterTodd Luman, Laser En- based ink systems that graving Manager at In- are designed to set at 2008: Interprint Buys terprint, recommended low temperatures and a Flexo Wash Grathey try a Flexo Wash cure fast. In stating vure Cylinder Cleaner Gravure Cylinder Clean- this, when we wash-up er. He states that they in the press we don’t

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get all of the ink out of the cells and require an off-press cleaning system.”

themselves obviously as we proceeded to purchase the system.” Interprint bought their Flexo Wash Gravure Luman got in touch Cylinder Cleaner in with Joe Almeida, Flexo 2008.

Wash territory manager and got a demo unit set INTERPRINT IS STILL up at Interprint. Luman USING THAT CLEANstates “A demo Flexo ER FROM 2008 TOWash system was DAY brought in and tested on several cylinders that Interprint has kept this were severely plugged. machine running and The results speak for continuously cleaning

for 14 years. We asked Luman to share what the secret was to longterm success with this cleaner?

“No secret really, just good old-school mentality of scheduling your machinery for maintenance before your machine schedules it for you. The system has lasted due to our preventative maintenance program and a dedicat-

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ed group of individuals (operators) who take pride in their work environment and respect the equipment they use.”

processing through the system (a lot of additional wear and tear, it may also be of inScheduled Mainteterest to nance Program mention the size of our Every other month all cylinders, the sprockets, shafts, which range chains and rollers in the in weight drive system are infrom 500 LBS spected for wear and to 2000 LBS replaced as needed. Ad- and up to 8’ wide to ditionally, the in-line oil- 1450mm circumferers are inspected and ence). “ refilled.

Detergent to clean the STATISTICS cylinders is added as needed to the holding Projected amount of cyltank. (The machine lets inders cleaned per us know when we need month: to make an add) Twice a year, the hold- The initial projection ing tank is emptied and was for the system to the sludge is removed, clean an average of 150 a fresh bath is made at cylinders per month. this time.

However, in reality, the Luman states “This does lowest month was dounot mean we have not ble that number since had premature equipwe started to track the ment failures. This hap- through put data in pens, things break.

2011.

However, I would contribute a fair amount of Size of cylinders: this due to the addition- Range in weight from al demand we put on 500 lbs. to 2000 lbs. Up the machine. Our equip- to 8’ wide to 1450 mm ment was designed and circumference. specked out to clean 1/3 the amount of cylinders we are actually

How many days a week and days per year in operation?

Pressroom operates with three shifts, 24 hours a day/five days a week. Total of 240 days a year.

How much time do you spend cleaning each roll now? How much time did you spend before the Flexo Wash Cleaner?

“The system is not faster than our previous cleaning methods, however it is safer on the cylinders. So, it may take twice as long to clean them with the Flexo Wash (about a 1520 minute cycle time) however, we are not damaging the cylinders which is a savings to us.

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This does not mean we couldn’t use a harsher chemical and crank up the heat during the cleaning cycle to increase the speed of the cleaning process. However, the end goal is not to damage the cylinders. So, if it takes longer to clean them, we are okay with this. “

made to best fit their needs.

Luman adds “a few things we take into consideration that weighs strongly on the final investment decision outside of the obvious (performance and price to a certain extent) has to do with the type of technical support/ How much are your service provided by the cleaning supply manufacturer. The techcosts? How does that nical support, plus the compare with before responsiveness and willthis cleaner? ingness to listen to our concerns provided by “The cost of everything Flexo Wash has been has gone up since our outstanding over the purchase back in 2008 last 14 years which reso we don’t have a fair assures us that Flexo baseline to compare Wash is a company that consumable costs. Nev- stands behind their ertheless, the cost of product and will support the cleaning supply is their customer’s needs. not a make-or-break factor for us. We need As mentioned previousan effective, environly, the support from the mentally safe, low VOC Flexo Wash group has cleaner and will pay a been fantastic. Joe Albit more to get the remeida in particular unsults we desire. “ derstands the industry, his equipment and has FUTURE GROWTH been pleasant to work FOR INTERPRINT with. Joe is open to hearing the good and As their business grows, taking the bad news as Interprint will require well in a positive, proadditional cylinder fessional manner and cleaning equipment in has supported us over the future and will asthe years to ensure we sess the market for were satisfied with the what technological ad- performance of our vancements have been equipment. “ 19

Geissmann Renews Its Confidence in Comexi with the Acquisition of a 10-Color F2 MP Press The flexographic printing press will allow the Swiss company to further strengthen its leadership position in the highly competitive Swiss market strategic loyal customer for many years," explains Ramon Jonama, the Comexi Area Manager of this region, who highlights that the F2 MP flexographic press is the third Comexi machine acquired by the Swiss company. Jonama emphasizes that "once again we are able to offer Geissmann the highest quality and technology, as well as impeccable service."

The 10-color F2 MP press achieves these objectives through great mechanical robustness, the most precise electronics and automation at the highest level. Consequently, it is of no importance the "We are very pleased to difficulty level of print orders; the maximum have Geissmann as a Comexi, a global supplier of solutions for the flexible packaging printing and converting sector, and Geissmann Papier AG, a Swiss company that specializes in the production of flexible packaging, have strengthened their strategic alliance with the acquisition by the Swiss company of a Comexi F2 MP. This central drum flexographic press machine, to be installed at the Dottikon headquarters in early 2022, will allow Geissmann Papier AG to further strengthen its leading position in the highly demanding Swiss market.

quality and productivity will be achieved repeatedly. In reference to long runs, the machine effortlessly prints at 500 m/min. Simultaneously, due to the builtin automation, job changeover and set-up are rapidly performed, which greatly increases productivity when runs are short.

Geissmann also benefits from the latest advances in service and spare parts. Comexi has invested a great deal, and constantly integrates the best human team, advanced diagnostic systems, as well as an exhaustive stock of spare parts that allows all the strategic parts and components

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ready to ship, etc. As a result, any problem, irregardless of size, is resolved in record time, and all Comexi machines, those installed many years ago as well as recently, unfailingly operate without interruption. Furthermore, production control and traceability are fully implemented.

ments, innovation, and new market orientation, Geissmann Papier AG presently produces, for many years, a variety of high-quality papers, films, and complexes.

These products are supplied in the form of reels and bags for the flexible packaging industry, primarily food, from a wide range of raw materials.

packaging sector. The F2 MP is the origin and basis of the F2 family, and so it features every ergonomic and robust solution of the F2 family.

It incorporates every GeniusTech solution that assists printers to conquer the main challenges they currently face, which include a lack of skilled operators, a job Founded in 1942 as a length reduction, and an family business, Geiss- "We have invested in increased number of job mann Papier AG is cur- this flexographic press changes, among others. rently managed by the because we know Between all GeniusTech third generation, with Comexi's excellent tech- solutions, maximum imDaniel Geissman as the nology. This press ma- portance has been given executive director; the chine has evident syn- to all these that focus in company employs apergies with our other providing the highest proximately 60 people. Comexi machines, both printing quality at high In the beginning, priprinting and laminatspeed, like the Gemarily mono films and ing," says Daniel Geiss- niusRun which elimicarrier bags were promann. The Comexi F2 nates the bouncing, the duced. Through compa- MP has been designed GeniusDry for the maxiny growth as well as to meet long run print- mum drying perforhigh machinery invest- ing needs of the flexible mances at high speed,

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and GeniusDoctoring for a trouble-free ink transfer. Sustainability has also been taken into account in the design of the Comexi F2 MP, so along with the different energy efficiency solutions we can find a dedicated version for Water Base inks, or a hybrid machine for Water Base, Electron Beam or Solvent Base inks.

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