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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