In terms of trending topics in the label and package printing industry, sustainability remains at the top across the value chain. A recent global survey from market research firm McKinsey & Company reveals that about 75% of organizations have made clear sustainability commitments toward packaging. However, the firm says, fewer than 30% are well prepared to meet regional requirements, much less internal aspirations. Thus, progress is ongoing, and there is much work to be done, as many brands and businesses still lack clear metrics surrounding recyclability, sustainability, or recycled content.

“Consumers value sustainably-sourced and manufactured products – so much so that this has led to 2.7 times faster growth for sustainable products versus traditional goods, despite price premiums over their conventional counterparts,” according to McKinsey & Company. “Meanwhile, policy makers and regulatory bodies are responding to public sentiment by implementing regulations related to single-use packaging while also placing extended producer responsibility (EPR) on consumer-facing products. Currently, Europe is leading the way on most of these regulations; however, governments in Asia–Pacific and North America are developing similar legislation. All trends in consumer preferences, regulations, and government actions point toward sustainable packaging becoming a key focus for sustainability efforts.”

In the post-pandemic world marked by inflation and supply chain disruptions, meeting sustainability goals has even greater challenges. Within the narrow web converting sector, advancements continue to be made that overcome obstacles while helping to further eco-friendly efforts in both B2B and B2C environments.

“Sustainability is more important than ever before,” says Avery Dennison. “Brands’ commitments on sustainability have accelerated as consumers demand action. Brand focus on sustainability is also driven by investors and the potential for regulation on sustainability disclosure. As a result, converters are also seeing this. Converters are now being asked more frequently to support these requests for sustainability disclosure, data, and transparency on their sustainability practices.”

Converters have responded, instituting numerous practices in their facilities to meet this trend. Penmar Industries, based in Stratford, CT, USA, has switched exclusively to water-based inks – eliminating all solvent-based inks – and converted to solar power with panels on its roof.

“One of my biggest goals when we moved into this facility was not only to make it a better environment for production, but also to be conscious of the community and our environmental footprint,” says Rick Cipot, Penmar’s operations and general manager. “One of the first steps was getting rid of solvent inks and going with water-based inks.”

Sustainability can also come in the form of energy – or saving energy, for instance. Curing specialists, such as GEW and Phoseon Technology, have enabled converters to cut down their energy usage by large margins by pivoting to UV LED curing.

The interest is palpable, too. US states, such as California and Washington, are already requiring beverage companies to include 15% PCR in their plastic containers.  This increase in demand can be felt in PCR resin pricing versus their virgin grade counterparts.

“Customer interest is coming from both sides of the value chain,” adds Avery Dennison. “Increase in consumer demand for sustainable solutions has large brands pushing for sustainable solutions and 2030 goals. On the other end of the chain, recyclers and MRFs are requesting laser focus on design for recyclability. The removal of detrimental and non-recyclable packaging is instrumental in increasing the yields, purity and output of recycled resin that can be used in a circular economy.”

Sustainable commitments are nearly universal. Fedrigoni Self-Adhesives, for example, has established a target of 2030 to have 100% of its standard product portfolio with a solution enabling recyclability or reuse of packaging. This might include recyclable materials, compostable solutions, or wash-off capabilities, with LCA on demand.

Melissa Harton, Fedrigoni’s marketing manager, North America, says, “Additionally, we look to have 95% of our supplier base qualified to ESG criteria, with pulp 100% covered by FSC claims.”

Sustainable substrates

Substrate suppliers have been at the forefront of sustainable R&D in the label and package printing industry. From thinner substrates to more recyclable materials, suppliers have dedicated significant resources to promoting a lighter carbon footprint.

Avery Dennison prioritizes sustainability in several ways, including a lofty 2025 goal to have 70% of its sales revenue from its Sustainable Advantage portfolio. Also, there are 2030 commitments to dramatically decrease its carbon emissions, featuring collaboration with a team to identify opportunities to reduce the emissions impact of its product portfolio.

UPM Raflatac has made the same guarantee. “UPM Raflatac’s ambition is to be the first label materials company beyond fossils,” comments Ashley Drew, sustainability manager, UPM Raflatac Americas. “We take climate action by increasing the use of certified papers and the traceability of other biobased materials, by fostering a reduction of greenhouse gas emissions and by developing innovative solutions that meet the needs of sustainably-minded brands and companies.”

Avery Dennison now offers CleanFlake technology on all film labels, enabling and advancing rigid plastic recycling. Regardless of application, AD CleanFlake Technology offers excellent performance on all types of packaging. This makes sustainability an easy choice for converters.

Plus, Avery Dennison has introduced four new facestocks to the company’s Wine and Spirits Sensorial Collection. All four are 70-pound wet-strength facestocks that employ 30-100% Post-Consumer Waste (PCW) paper.

Fedrigoni Self-Adhesives has prioritized paper with its wide range of customers. “Whenever possible, we opt for paper as our primary raw material,” states Harton. “Paper is a renewable resource and has a lower environmental footprint compared to other materials. We only resort to using plastic when it is necessary for specific product requirements. This deliberate decision ensures that we minimize our use of single use plastic and prioritize more sustainable alternatives.”

For filmic facestocks, UPM Raflatac provides clear, white and metalized films that feature the company’s RW85C wash-off adhesive. The portfolio offers wash-off label materials for different packaging material types that allow labels to be cleanly separated from the primary packaging in a recycling process without leaving adhesive residue, thereby enhancing yield of the recyclate and increasing the availability of recycled and reusable materials.

“At UPM Raflatac, we adhere to the philosophy that ‘labels matter’ when it comes to enabling the recyclability of packaging materials,” adds Drew. “Brand owners looking to achieve their sustainable packaging targets can be confident when they select our labeling solutions.”

Association of Plastic Recyclers (APR) certification signifies a substrate supplier’s commitment to sustainability. For example, Mactac recently earned the recognition for its polypropylene pressure sensitive label materials with a hot-melt adhesive for high-density polyethylene (HDPE) containers. During Critical Guidance testing, Mactac labels demonstrated compatibility with standard HDPE container recycling practices and remained in place without impacting the physical properties of the recycled HDPE pellets. 

Recognized products include white and clear top-coated polypropylene labels that are paired with the Mactac CHILL AT adhesive (PJ7802, PJ7892-2, PF7802 and PF7892-2). CHILL AT is an all temperature hot-melt adhesive designed for food packaging, as well as a variety of other applications, including home and personal care.

“Achieving this recognition is an important step in our company’s Simply Sustainable commitment to promote a more circular economy,” comments Kim Hensley, senior marketing manager, Mactac Performance Adhesives.

Fedrigoni recently introduced to the North American market its APR-certified wash-off product. RI-MOVE PET’s AR842 adhesive provides debonding of non-recyclable label materials from PET containers, thus making them recoverable. Debonding occurs when a container is processed utilizing a water temperature of 88 degrees C/190 degrees Fahrenheit or higher with an alkaline solution.

“This sink/float recycling process cleanly separates the label from the container and PET flakes,” says Fedrigoni’s Harton, “The PET fragments, now clean and residue free, can be used in a PET bottle-to-bottle recycling process. RI-MOVE products are recommended for beverage and household applications where the container will pass through its recycling stream and the PET flake process.”

Meanwhile, Avery Dennison recently announced that its metalized film substrates with AD CleanFlake technology have been recognized by the APR for HDPE and PET recycling. The company says, “We are the first to be recognized for offering a portfolio of metalized label solutions capable of working with the recycling systems to enable rigid plastic recycling.”

Avery Dennison has also placed a premium on linerless labeling. At the tail end of 2022, Avery Dennison unveiled its Direct Thermal Linerless portfolio. Linerless labeling technologies have picked up steam lately, especially as the supply chain realizes the environmental benefits.

“Eliminating the liner on direct thermal blanks allows customers to get up to 50% more labels per roll,” says Avery Dennison. “This leads to fewer roll changes, speeding operations and improving warehouse utilization. The Avery Dennison blank linerless labeling solutions offer productivity, sustainability, and safety benefits.”

Digital advantage

The digital printing process is inherently sustainable compared to conventional print methods such as flexo or offset. Reductions in waste, setup time and materials, coupled with the removal of printing plates from the process, all lead to more eco-friendly label manufacturing.

Xeikon’s new Cheetah 3.0 technology has been optimized to leverage sustainability. The new Xeikon ECO toner has been formulated with over 60% high-grade repurposed PET, making it the ideal solution for environmentally-conscious packaging applications, ensuring compliance with the increasingly stringent regulations governing packaging components and recyclability.

To guarantee the highest quality and lower waste (hence lower cost), Xeikon has also developed the Quality Measurement Module (QMM). The QMM will be responsible for the quality assurance of the printed output, closely monitoring the density and registration throughout the print run. 

Xeikon has targeted sustainability in flexible packaging, too. The company will premiere its new TITON toner technology at Labelexpo Europe. The product has been developed to meet market demands for paper-based flexible packaging applications: stand-up pouches and sachets. 

“Xeikon has also devised a new Sustainability Scorecard, which offers a more transparent means of proving compliance with various regulations and also help brand owners with their sustainability goals,” says Donna Covannon, director of marketing at Xeikon North America. “The Scorecard will analyze the carbon footprint of each Xeikon press.”

Label King, a prominent converter based in San Diego, CA, USA, has noted the sustainable benefits of installing a digital press. The company recently entered the digital printing realm with a Domino N610i digital UV inkjet label press.

One of the key advantages that digital brings to label printing is a reduction in material waste. When compared to Label King’s flexo jobs, the company is using less material running on the Domino press.

“Our shop rule is if there is 500 feet or less of material remaining on a roll, we would generally throw it away because we can’t print a flexo job on that,” explains Turi Fiske, digital production and marketing manager, Label King. “However, today we printed a 300-foot job running that material through the Domino, and we have a pile of those small rolls. So we are now able to maximize our material usage. It not only saves material but it also saves time. It’s just a quicker and more efficient process.” 

Think ink

Much like substrates, inks are every bit as critical in the sustainability of a label’s construction. Flint Group has unveiled a new sustainability framework. 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.

“In today’s highly competitive market, printers need confidence that their vendors can help them lead in sustainable packaging via responsibly sourced, sustainable materials,” notes Matthew Rowland-Jones, sustainability officer at Flint Group. “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. But more importantly, this framework will see us overhaul our business. PRISM lays the groundwork for transformational change, from reducing waste to caring for and diversifying our workforce.”

INX International Ink Co. has followed suit, targeting sustainability with new investments. INX has completed an investment in Debut, a vertically-integrated synthetic biology company that is developing innovative and complex active ingredients for natural colors, among other materials.

Debut’s proprietary biomanufacturing platform uses “cell-free” and other advanced approaches, such as continuous biomanufacturing, to address the limitations of traditional methods, dramatically reducing the need for space, water, and expensive and unsustainable inputs. In addition to producing rare, high-value, and novel compounds, Debut’s technology also improves traditional ingredient manufacturing. By overcoming the limitations of cell-based fermentation, Debut can produce high-value ingredients rapidly and more sustainably.

“We established our corporate VC fund to accelerate growth for promising startups that are connected to INX’s strategic missions,” states Bryce Kristo, INX president and CEO. “We see Debut Bio as an emerging leader in the synthetic biology space that can play a key role in moving ingredients and materials to a more sustainable, circular economy.”

Meanwhile, Sun Chemical has boosted its sustainable inks with dedicated facilities to target sustainability. The company’s initiatives have not gone unnoticed, either. Sun Chemical has been recognized with the 2023 Flexographic Technical Association’s (FTA) Sustainability Excellence Award for Innovations in Sustainability, an achievement in sustainability in the packaging industry.

The award recognizes Sun Chemical’s portfolio of mono-web protective coatings, which enable mono-web film structures as alternatives to lamination structures common in label and flexible packaging such as wrappers and pouches. The transition from lamination to mono-web structures can save on the use of adhesive, film, processing time and final label weight – all of which reduce the environmental footprint and use of virgin resources.

“Sun Chemical is excited to be awarded with the FTA’s Sustainability Excellence Award this year,” says Heather Buchholz, manager, global marketing, Sun Chemical. “To be recognized for our mono-web coatings and the impact they have on driving circularity in packaging is tremendous, as it recognizes our approach and commitment to the market. And we’re not done.”

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Discover energy credits and state incentives for UV LED curing technology

Sustainability has risen on the agenda, but power consumption has brought the economic aspect to the table. In the past 12 months, energy prices have increased 50-88% on a global scale. Have you considered
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Titan Energy (CT) has worked with end users to identify and apply for rebate/funding dollars toward the purchase of UV LED curing systems. Titan Energy is an independent energy consultancy firm with in-depth knowledge of energy procurement, demand-side management, and on-site generation services helping customers throughout North America. As a leader in the energy management industry, Titan Energy’s ability to generate savings associated with reduced overall consumption has created a trusted reputation throughout North America. 

Titan Energy creates comprehensive energy management strategies utilizing data to control and reduce energy costs. Utilities nationwide are looking for large energy users to curtail energy use and are willing to fund energy efficiency projects.

The results were evident in a recent case study. A leading North American manufacturer of premium prime label solutions sought to reduce its carbon footprint and become more energy efficient in their processes. By working with Titan Energy to plan energy efficiency upgrades, they found opportunities to improve the sustainability of their printing company, reduce printing costs, and reduce energy usage.

By upgrading exhaust fans, converting mercury vapor lamps to Phoseon UV LED curing systems, and upgrading the printing line on three presses, the manufacturer was able to reduce its CO2 emissions by 4,755 tons, SO2 emissions by 5,531 pounds, and its NOX emissions by 6,519 pounds. In addition, the printing line’s energy use was reduced by over 50% with the new UV LED curing systems.

Not only was the energy demand reduced, but the lamp life increased from 2,500 hours to 25,000 hours – a 10,000% increase, meaning the converter only needs to replace the bulbs once every four years instead of three times per year, saving in material and maintenance costs. These reductions were possible because the new LED lamps that were installed have a lower wattage than the UV and mercury vapor lamps and are less energy intensive.

Additionally, the new lamps generate less heat, so the facility has reduced chilled water requirements and exhaust fans to keep the printing line running properly, which reduces the energy usage further. The old mercury vapor lamps also needed to remain in “stand-by” mode in between production runs, but the new LEDs are either on or off, which saves additional kWh. With savings from this project, the manufacturer has been able to reinvest funds into other facility improvements, such as adding four new printing presses in their plants, creating over 30 new jobs. Phoseon UV LED curing technology increased production pace, cutting project turnaround times in half while maintaining consistent quality.

For more information about UV LED curing technology or energy incentives, please contact Phoseon, An Excelitas Technologies Company at https://phoseon.com/contact-us/.