In-Line Printing and Laminating with EB Curing for Packaging

Applications

Im Rangwalla Radtech Europe 2013

Basel Switzerland

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

Dollar Value of US Flexible Packaging Market 1998-2012

Year

1996 1998 2000 2002 2004 2006 2008 2010 2012 2014

$ Bi

llion

s

12

14

16

18

20

22

24

26

28

Flexible Packaging Industry Major Processing Categories

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Printing Laminating Coating Extrusion

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

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

EB LAMINATING ADHESIVES ADVANTAGES

FEATURE

BENEFIT

INSTANT CURE

LESS LABOR- NO WAREHOUSING

INSTANT CURE

LAMINATE TO EDGE

INSTANT CURE

REAL TIME QUALITY CONTROL

INSTANT CURE

REDUCE INK COST, ELIMINATE ADHESIVE ETCHING OF INK

TAILOR MADE VISCOSITY, WIDE RANGE APPLICATION METHODS

CAN USE EXISTING COATING EQUIPMENT

EB Laminating Adhesive Market Value/Performance

HighRetort,

Aqueous Foods

MediumMeat&Cheese,

CoffeeSnacks

LowBottle labels, Dry Foods

EB

Flexography solvent Based Ink With In-Line EB Laminating

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 roto-gravure 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

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

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

Technical Developments

Gravure for flexible packaging No new developments

Flexo for flexible packaging •General flexography technology, Photo polymer plate dvlpmnt • Water based EB Flexo • EB Cured-Flexo Ink

Sheet-offset for labels and folding cartons

No new developments

Web-Offset for folding cartons and flexible packaging

Variable formats/repeat Central Impression CI-8

Variable Sleeve Offset Printing (VSOP)

With EB Curing

Using sleeves like in flexo

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

VSOP PRESS EZCure-I DF EZ110/90/1000

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 850- 1250mm

– Print Repeat Lengths 381- 762 mm & 570-1120 mm

CI-8 EB Offset Technology

Converter Printing Comparison Flexible Packaging

Print Type

2007 2009 2011

FLEXO 67% 65% 64% GRAVURE 11% 10% 11% OFFSET 1% 1% 5%

UNPRINT 22% 20% 19%

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

Method of achieving wet trapping by evaporating non-reactive diluent and increasing viscosity of the

applied layer

WO/2010/071952 Dec, 2009 Technosolutions Brazil

Method of achieving wet trapping by evaporating a non- reactive

diluent and forming an organo gel in the applied layer

WO/2011/091364 Jan, 2011 Sun Chemical USA

Method of achieving wet trapping by controlling the storage modulus of the

ink. Each applied ink layer will have decreased modulus

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

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

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.

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

Thank You Vey Much For Your Attention