While cost and quality concerns have long impacted the presence of environmentally friendly materials in the flexographic pressroom, brand and consumer demand is necessitating a shift in our industry. Converters and suppliers alike are focusing on the creation of a circular economy to help brands meet their lofty goals. 

From a 30,000-foot view, society as a whole struggles with sustainability. The US alone is consuming at a rate of 5.1 Earths, with the world consuming 1.75 Earths, on a yearly basis. The globe hit capacity on August 2 in 2023, showing our practices are not tenable.

While 47% of the top 500 companies have reduced emissions, the overall net gain is still 1.5% as 29% of the top companies have increased emissions. Society needs an 8% annual reduction in emissions YoY to meet 1.5C decrease by 2050.

These issues and more were discussed at FTA’s Forum and INFOFLEX, which took place May 5-8, 2024, in Kansas City, MO, USA. A panel of industry experts targeted the latest trends in flexo printing, exploring what the future holds in this arena.

From labels to flexible packaging, there are inherent challenges. In flexible packaging, many films can’t effectively be recycled, while end users are unwilling to pay twice the amount for compostable films.

However, companies are making strides. For example, Emerald Packaging, certified as a California Green Business, has prioritized sustainability tiers, practices, materials, and adherence to legislation. The company also captures 99.9% of VOCs, and if it doesn’t hit those numbers, the presses don’t run.

“We recycle 99% of everything we do, as our ink gets reworked and solvent gets recycled,” explained James Dye, press manager, Emerald Packaging. “We use automation in manufacturing to prevent the over-mixing of chemicals and adhesives. Our machines also use less temperature, energy, water and overall resources to meet throughput standards.

“At Emerald Packaging, holistically, we’ve introduced 5% PCR into all our resins and films,” adds Dye. “Among our customers, our top three accounts have made a 30% commitment to use PCR.”

An FTA poll showed 87% of members have undertaken internal sustainability goals. Companies are currently tracking electricity consumption, landfill waste, water consumption and more – and the biggest contributor to waste is substrates.

Other challenges include the perception of recyclable materials. Notably, food waste is responsible for 6% of global greenhouse gas emissions, said Dye, but there is a call to ban packaging that extends shelf life. There are initiatives to shape legislation across North America requiring single-use packaging to be recyclable by 2030.

“We as a manufacturing industry need to push for reasonable legislation and have it make sense for producers, users, and customers,” stated Dye.

Among other goals, the label and package printing industry needs to advocate for circularity, create recyclable packaging where possible, prime the PCR supply chain by facilitating demand, and work on source reduction by designing and manufacturing sustainable materials.

“Over the last five years we’ve made significant improvements,” said ePac’s Amy Golden. “PCR is widely available, and the demand for sustainable packaging is on the rise, from the consumer, brand, and converter.”

“There are many associations across the globe working to design guidelines and good practices, such as RecyClass, Ceflex, and our very own APR in North America,” added Siegwerk’s Ashish Datt.

The switch to LED plates has been a flexographic focus, too. DuPont’s Allie Ayers cited 41% energy savings for a trade shop with an average plate consumption of 13 plates per 8-hour shift, with 59% energy savings for a converter with an average plate consumption of six plates per shift. The reduction of waste can be traced to no longer needing to replace UV lamps containing mercury every 800 hours.

“DuPont is continuing to invest in thermal plate processing, which is commonly seen in the narrow web market,” added Ayers.

Thermal plate processing has been associated with 81% lower electricity consumption and 99.8% lower VOC emissions.

Miraclon’s John Anderson also focused on the flexo plate’s role in sustainability. “For me flexo plates and flexo printing are really important and they’re key parts of sustainability,” he stated. “The question is what’s happening to the plate on-press? What happens on-press outweighs what the plates can do for sustainability. I agree, LED is the future, but we need to explore how we make it better for the brands and the end users.

“The plate is driving efficiency, from slitting, lamination and even extrusion – through the whole process,” he added.

The FTA Fall Conference will emphasize sustainability, as well. According to Anderson, the industry needs to get behind initiatives like the Consortium for Waste Circularity.

“We’re moving toward a place of doing more with less,” explained Anderson. “We have to reduce dot gain and keep it consistent, and control unwanted ink spread. The No. 1 enemy for me is spot colors. The more we can move to process printing, the better we’ll be. Spot colors are the most expensive option to run in flexo, since inks are expensive and volumes are high – and you need anilox changes, extra drying, etc., and that slows the press speed.

“Let’s make our presses more efficient and more profitable,” concluded Anderson.