A Cooperative Project
between the
U.S. Environmental
Protection Agency
and the
Printing Trade
Associations
Nationwide
March 1997
EPA 744-F-96-013
                                                                            FLEXOGRAPHY PROJECT CASE STUDY 1
CAS"E~"STU~D
HIGHLIGHTS)
          |is CASE STUDY)
 • Facility Profile
  Areas of the Facility
•Commitment from Management
               A    CASE    STUDY
Reducing VOCs in Flexography
                    This case study highlights the experience of one wide-web flexographic printer that
                    successfully reduced volatile organic compound (VOC) emissions and hazardous 'waste
                    by switching inks. While every facility is unique, it is hoped that the information pro-
                    vided can help even very different flexographic printers. In particular, this case study
                    shows:
                        =*> how a Water-based illk System and water-based cleaning
                          procedure can reduce VOC emissions, hazardous waste, operating costs,
                          and worker health risks
                        =£> how the printer overcame challenges to print successfully
                          •with water-based inks


                 Company Background

                    Highland Supply Corporation CHSQ, at its Highland, Illinois
                    facilities, manufactures decorative packaging products for the floral industry.
                    Its product line includes printed and laminated films, foils, and paper. In 1988,
                    HSC made it company policy to reduce or eliminate air emissions and hazardous
                    waste generation. HSC focused on reducing one of its primary emissions, VOCs,
                    for two reasons.  First, HSC was aware that VOCs can be harmful to •worker health
                    and the environment. Second, HSC predicted that federal and state environmental
                    regulations for VOCs would become more stringent in the future.

                    The company found that its solvent-based inks (50% VOCs by weight) were the
                    primary source of its VOC emissions.  To reduce these emissions, the company
                    initially looked into installing air pollution control equipment such as solvent recovery
                    or oxidizers. But if future regulations were to require further VOC reduction, these
                    units could not be easily adapted. In addition, the electricity and natural gas required
                    to run them would be expensive. HSC decided instead to reduce its VOC emissions
                    by replacing its solvent-based ink system with a water-based system.

                                                                                 Design for the Environment Q

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       llgtg	II
       on the season)"
f11	!	"'	•	l25to	150	million"
	tmamA	n	,SH!SfiLlsm	S!ffi,w»!'Y n'om
       fiexographic presses

   IMhjtoitet^
       Decorative packaging
       for the floral industry
   Plant Size:
       50,000 square feet
   Prinfin§ Presses:
       Five fiexographic and
       ten rotogravure presses
   Pdmaiy We
       Water-based ink
       (100% of product sales)
   Primary Substrata:
       Polypropylene
       (85% of product sales)
   Type of Printing:
       Reverse and surface
       Line and process work


   QDeitsfl for the Environment
                                           Water-Based Ink System
                                               In 1989, HSC began using a. new water-based ink on two rotogravure presses.
                                               The following year, water-based inks were tested on the fiexographic presses.
                                               By 1991, HSC was using the water-based ink on all its presses. Water-based inks
                                               now account for 100% of the total ink used in the facility.

                                               When HSC first used the water-based ink system, the company encountered a
                                               number of new challenges, including some adverse customer response to the
                                               print quality of the inks. However, HSC was dedicated to the system and
                                               conducted many hours of research and testing. The company modified presses
                                               and changed internal color standards.  Some other challenges HSC encountered,
                                               and the corresponding solutions, are listed below:
                                           Challenges encountered with the water-based ink
                                              U   Drying of the ink was incomplete
                                              Ed   Water fastness was insufficient


                                              cJ   Print quality was variable


                                              EJ   Ink adhesion was insufficient

                                              £U   Printing metallic inks was difficult


                                              D!]   Printing UPC symbols was difficult
                                                   Cleaning the anilox rolls and plates
                                                   was difficult because the water-based
                                                   inks would not resolubilize
HSC's solutions
=*>  Improved drying systems by
    lowering temperatures and
    increasing air flow rates

=£>  Continuously improved ink
    formulations and additives

=£>  Monitored the pH and viscosity
    of the inks

=?>  Installed a corona treater

=£•  Continuously improved ink
    formulations and additives

=£>  Printed the white UPC symbol
    background with a water-
    based, high density ink

=*>  Installed an ultrasonic cleaner;
    switched to a citrus-based
    cleaner; allowed more time
    for cleaning
                                           Environmental Benefits
                                               VOC Emissions Were Dramatically Reduced
                                               In 1989, HSC's water-based,ink contained 10% to 12%VOCs by weight. By 1996, the
                                               average VOC content for water-based ink formulas was down to 0.71% VOCs by
                                               weight, according to HSC. The few VOCs remaining in the water-based inks are from
                                               dispersions and surfactants. HSC recently bought new equipment to use in creating
                                               its ownVOC-free dispersions.

                                               This reduction in the VOC content of the inks, along with the elimination of solvents
                                               in other areas of the facility, had a dramatic effect on HSC's total VOC emissions. The
                                               following graph  shows the company's annual VOC emissions for 1989,1991,1993,
                                               1995, and 1996, as reported to the Illinois Environmental Protection Agency.

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                        VOC Emissions at Highland Supply
                   1989
Hazardous Waste Was Eliminated
The water-based ink system contributed to another important benefit.  HSC reports
that it completely eliminated hazardous waste from waste ink and cleaning operations
in 1994,1995, and 1996. HSC generates a small amount of nonhazardous solid waste
from disposable cleaning wipes.

Recycling Waste Ink
HSC also reduced the amount of total waste generated by recycling its water-based ink.
When the company first used water-based inks, the waste ink was solidified and sent to a
landfill under a nonhazardous waste permit. Recycling of the water-based inks began in
1992. By 1995, HSC recycled 99% of its waste water-based inks. Press return ink is stored
in a separate container labeled with the formula ID number until it can be blended back
into virgin ink of the same color. New colors can also be made, and hard-to-match waste
ink can be made into dark green and black inks.  HSC also added a computer with a col-
orimeter and scanner to facilitate better blending of the recycled inks.
Economic Benefits
    Reduced Ink Costs
    HSC's new water-based inks cost less per unit area printed. This is because HSC's
    water-based inks have a higher ink mileage than the previously-used solvent-based inks.

    Hazardous Waste Disposal Costs Eliminated
    Since hazardous waste is no longer generated, HSC spends very little on disposal
    costs. Solid nonhazardous waste disposal costs totaled less than $1,000 in 1996.

    Labor Hours Saved
    When HSC switched to water-based inks, some permitting requirements were
    eliminated. HSC avoided the labor costs needed to meet these requirements.
    If HSC was still using solvent-based inks today, more than 100 tons of VOCs would
    be emitted each year, making HSC a "major source" under Title V of the 1990 Clean
    Air Act Amendments.  Since HSC is not a "major source," it has avoided spending
    significant labor hours to prepare and file initial permit applications, and will save
    additional labor hours every year in years to come.

    In addition, HSC reduced flammable liquid usage below Occupational Safety and
    HealthAdministration (OSHA) reporting thresholds (Process Safety Management,
    OSHA 1910:119). Being exempt from this regulation saves HSC significant labor
    hours in the first year and additional labor hours in subsequent years.
    VOC emissions decreased
fe§j}9% in seven years. The
        VOC emitted in 1996
*SffeVy^s dipropylene glycol
    methyl ether, which is not
    a hazardous air pollutant
    (HiAP) and is not a reportable
    VOC under the Clean Air
    Act Amendments.
                                                                                   II
                                                                                   jf£g^y -„-- _ :,..,; ,'' .
                                                                                                    in VOC

                                                                                       'emissions and hazardous
                                                                                       waste occurred even as
                                                                                       v"y-":  _      "•"-."
                                                                                       iH§C's production more than
                                                                                       B:B- ---- ',.      -
                                                                                       i doubled from 1988 to 1995.
    Eliminating Solvents
    In Other Areas

    Highland Supply Corporation
    has stopped using tradition-
    al solvents in adhesives,
    cleaning, and maintenance.
    For example:

    =* In 1992, HSC installed
    an ultrasonic cleaner to
    clean anilox and plate
    cylinders.

    =*> In 1993, HSC replaced
    other traditional solvent-
    based cleaners (methyl ethyl
    ketone, methyl isobutyl
    ketone, and toluene) with
    a mixture of water and
    d-limonene (a citrus-based
    cleaner).

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If you would like more
information about Highland
Supply Corporation and their
experience with water-based
inks, contact:

Gene Wall,
Environmental Manager
Highland Supply Corporation
1111 Sixth Street
Highland, IL  62249
Phone: (618) 654-2161 x 417
Fax: (618) 654-3411
Partners In the DfE Hexography
Project Include: California Film
Extruders and Converters
Association (CFECA), Flexible
Packaging Association (FPA),
Flexographlc Technical Association
(FTA), Industrial Technology
Institute (m), National Association
of Printing Ink Manufacturers
(NAPIM), Plastic Bag Association
(PBA), RadTcch International, N.A.,
National Institute of Standards and
Technology (NIST), Tag and Label
Manufacturers Institute, Inc. CTLMI),
University of Tennessee COT),
Western Michigan University
(WAIU), and Individual printers
and suppliers.

a Design (or the Environment
                                       Other Benefits

                                       Additional benefits that improve HSC's safety, working conditions, marketing,
                                       and public image include:

                                               =£> eliminated health risks related to VOC exposure
                                               =£• reduced fire hazard
                                               =£• eliminated need for expensive explosion-proof storage
                                               =» improved public image and community relations
                                       Commitment From Management and Employees
       Company-wide commitment was essential to the success of HSC's switch to
       water-based inks. To strengthen this commitment, management integrated
       recycling and pollution prevention standards into the job descriptions for
       each employee, implemented aggressive health and safety programs, and
       conducted an internal pollution prevention assessment.

       With a commitment from management and continuous improvement in the
       printing process, your company can also realize the benefits of reducing VOC
       emissions and hazardous waste.
                                        About the Design, for the Environment Flexography Project

                                        The goal of the Design for the Environment (DfE) Flexography Project is to provide flexographers
                                        with information that can help them design an operation which is more environmentally sound,
                                        safer for workers, and more cost effective.

                                        The partners of the DfE Flexography Project, in a voluntary cooperative effort, are evaluating
                                        three different ink technologies: solvent, water-based, and UV-cured. Information is being
                                        gathered on the performance, cost, and health and environmental risk trade-offs of several
                                        inks within each technology.
In addition to the Flexography Project, similar DfE projects are currently
underway with both the screen printing and lithography industries.
Mention of trade names, companies, or commercial products does not constitute endorsement
or recommendation for use by either the U.S. Environmental Protection Agency or other firms,
organizations, or individuals •who have participated in the preparation of this publication.
  To obtain additional copies of this or other bulletins and case studies, or for more information
  about EPA's Design for the Environment Program, contact:
                 EPA's Pollution Prevention Information Clearinghouse (PPIC)
                                       U.S. EPA
                                 401 M Street, SW (7409)
                                 Washington, DC 20460
          Phone: (202) 260-1023                        E-mail: ppic@epamail.epa.gov
          Fax: (202) 260-4659                          DfE Web page: http://es.inel.gov/dfe
                                             Recycled/Recyclable

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