In-Line Printing and Laminating with EB Curing for Packaging Applications. Im Rangwalla Radtech Europe 2013 Basel Switzerland

Transcription

1 In-Line Printing and Laminating with EB Curing for Packaging Applications Im Rangwalla Radtech Europe 2013 Basel Switzerland

2 Global Flexible Packaging Market By Region Total $ 65 Billion Source FPA N America 30 % N America 7% C&S America 25% Europe 5% Africa M East 33% Asia Pacific

3 Dollar Value of US Flexible Packaging Market $ Billions Year

4 Flexible Packaging Industry Major Processing Categories 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Printing Laminating Coating Extrusion

5 LAMINATING ADHESIVES CURRENTLY USED Adhesive Type Market Share Growth Typical Chemistry Typical Cure Time Water Based Adhesives 10 15% Flat Isocyanate 1-2 Days Solvent Based Adhesives 50 60% Flat Decline Isocyanate, Ethyl Acetate 1-2 Days 100% Solids Solventless 25 40% Growing Isocyante 1&2 Part 3 Days

6 Advantages of EB laminating Adhesives Instant Cure: Immediate shipping available No Toxicity Concerns of Isocyanates or residual Aromatic Amines In-Line Printing and Lamination Compatible with commercial inks Excellent laminate appearance

7 EB LAMINATING ADHESIVES ADVANTAGES FEATURE BENEFIT INSTANT CURE INSTANT CURE LESS LABOR- NO WAREHOUSING LAMINATE TO EDGE INSTANT CURE INSTANT CURE TAILOR MADE VISCOSITY, WIDE RANGE APPLICATION METHODS REAL TIME QUALITY CONTROL REDUCE INK COST, ELIMINATE ADHESIVE ETCHING OF INK CAN USE EXISTING COATING EQUIPMENT

8 Value/Performa nce High Retort, Aqueous Foods EB Laminating Adhesive Market Medium Meat&Cheese, Coffee Snacks EB Low Bottle labels, Dry Foods

9 Flexography solvent Based Ink With In-Line EB Laminating

10 EB laminating Adhesive Technology Summary Excellent film bonding properties has been achieved with multiple substrates. BOPP, PET, LDPE based sealant films, Aluminum Foil, and Paper Board. Excellent bond performance with commercial flexo and rotogravure ink systems Laminate exhibit good water, and food resistance. Suitable for food packaging FDA compliance no taint or odor. Retort Compliance still a challenge Cost compatible with other incumbent time cured adhesive technology Capital Cost Justification Challenging

11 Commercial Status of EB Laminating Adhesive Technology Commercial In-Line solvent based rotogravure printing and EB Laminating for Dry Detergent. Structure OPP/EB adhesive/gravureprint /PaperBoard OPP Provides MVTR Commercial In-Line solvent based Flexo Printing and EB Laminating for Paper Reams Structure OPP/Solvent Based Print/OPP Commercial In-Line water based stack Flexo and EB laminating Adhesive for BaseBall Cards Structure OPP/WaterBased Flexo/Metallized OPP Line speeds over 350mpm achieved Good Success With Commercial solvent and water based Flexo & Gravure Inks

12 Challenges Faced By Converters Runs Getting Shorter Market Demand For Sharper and more Graphic Changes JIT Reduce Inventory and Run Lengths Graphic Quality Keeps Increasing Frequent Design Changes Cost Needs to Come Down Color Match Globally Sustainable Packaging

13 Technical Developments Gravure for flexible packaging No new developments Flexo for flexible packaging Sheet-offset for labels and folding cartons General flexography technology, Photo polymer plate dvlpmnt Water based EB Flexo EB Cured-Flexo Ink No new developments Web-Offset for folding cartons and flexible packaging Variable formats/repeat Central Impression CI-8

14 Variable Sleeve Offset Printing (VSOP) With EB Curing Using sleeves like in flexo

15 Advantages of EB Curable VSOP Technology Excellent Print Quality. Like Gravure Sleeve Technology allows Fast Response from Printer to Customer Multiple Ink Suppliers Competitive For Short Runs High Speed 400 meters/min Possible Print on Broad Range of Substrates Established Print Technology NO VOC and Food Packaging Friendly In-Line Printing Coating or Laminating

16 VSOP PRESS EZCure-I DF EZ110/90/1000

17 Status of EB Curable Offset Print Technology Multiple lines operating in Europe and America for Food and Non-Food packaging. Broad Range of Substrates. Mostly Paper & Paperboard. Some Plastic Films. Many Global Offset-Ink Suppliers. Commercial Production at 350 meters/min Web Widths mm Print Repeat Lengths mm & mm

18 CI-8 EB Offset Technology

19 Converter Printing Comparison Flexible Packaging Print Type FLEXO 67% 65% 64% GRAVURE 11% 10% 11% OFFSET 1% 1% 5% UNPRINT 22% 20% 19%

20 EB CI-Flexo Technology Development Patent or Application Number Filing Date Assignment Abstract US 5,690,028 June, 1996 Cavanaugh Corporation USA Method of achieving wet trapping by heating the subsequent ink to reduce viscosity US 6,772,683 Feb, 2002 Sun Chemical USA WO/2010/ Dec, 2009 Technosolutions Brazil WO/2011/ Jan, 2011 Sun Chemical USA Method of achieving wet trapping by evaporating non-reactive diluent and increasing viscosity of the applied layer Method of achieving wet trapping by evaporating a non- reactive diluent and forming an organo gel in the applied layer Method of achieving wet trapping by controlling the storage modulus of the ink. Each applied ink layer will have decreased modulus

21 Advantages of EB Curing CI-Flexo Technology NO VOC NO Incineration or Recovery System Very Low Energy Consumption Compared to Heat or UV Curing Curing/Drying Systems No Ovens No Inter-station Drying No Remaining Solvents Stability/Handling No Dry-In No Press Side Adjustments Water Washable

22 Advantages of EB Curing CI-Flexo Technology EB CI-Flexo Process In-Line Printing and Laminating Performance Advantages High Gloss High Definition Graphics Dot Structure and Dot Gain Higher Line Screen Up to 70 L/cm High Color Efficiency Finer Anilox Less Ink Consumption Crosslinked Systems Instant Cure Scratch & Solvent Resistance Heat Resistance Food Packaging Compliant No Photo Initiator No Odor/Taint

23 Status of the EB CI-Flexo Ink Process Installations in Americas and Europe For Food & Non- Food Packaging Multiple Ink Suppliers & Technologies Wet trapping by evaporation of non reactive diluent & forming viscosity gradients in trapped layers. Wet trapping by evaporation of non reactive diluent & forming organo gel. Wet trapping by thermally drying water in between decks and curing finally with EB to improve printed ink properties Retrofit For Existing CI-Flexo Press. EB Press with NO Dryers for first 2 technologies Broad Range of Substrates. Paper, PE, OPP, PVC, Aluminum Foil On-Site Demonstration available at Major Flexo Press Manufacturers.

24 In-Line EB Printing and Laminating Makes Sense Instantaneous Cure Provides JIT Market Demand EB Cured Flexo and Offset Inks Provide Higher Print & Graphic Quality Quick turnovers and make ready with EB printing and in-line laminating provides quick turn around for shorter runs EB Curing Offers Solventless Printing and Laminating with the lowest Carbon Foot Print Capital Cost of EB equipment is shared by curing inks and laminating adhesives together In situ curing of inks & laminating adhesive using similar chemistry poses less challenges than laminating EB cured inks with conventional PU type adhesives and vice versa. New low voltage EB equipment are designed for lowest Power Consumption and least affects on substrates

25 Thank You Vey Much For Your Attention