Dr. Simon Daplyn, Product and Marketing Manager at Sun Chemical, delivered an engaging and insightful presentation titled “Print, Pack, De-Ink, Repeat” at FuturePrint, focusing on the role of digital print in achieving greater circularity in packaging. Daplyn addressed key challenges and opportunities in the digital packaging sector, emphasizing the importance of sustainability, de-inking, and innovation.
Digital Print: Dispelling Myths
Daplyn began by challenging common misconceptions about digital print in packaging. He debunked the notion that digital print is too slow, pointing out that modern presses, such as those showcased at drupa, can operate at speeds of up to 350 metres per minute. He also addressed cost concerns, arguing that while digital inks may appear more expensive per litre, they offer significant savings through reduced waste, faster changeovers, and enhanced brand value via high-performing inks that maintain quality throughout the product lifecycle.
Moreover, Daplyn highlighted how digital print supports the growing demand for agility in packaging. Shorter runs, versioning, and personalisation are increasingly prevalent, and digital print is uniquely suited to meet these needs. Citing research from Smithers, he noted that declining run lengths are driving a surge in print jobs, with over a million additional jobs annually in carton board alone—a trend that aligns perfectly with digital print’s strengths.
De-Inking: A Critical Enabler of Circularity
The core of Daplyn’s presentation focused on de-inking—the process of removing printed ink from packaging materials to facilitate recycling. As the industry moves toward circular packaging, de-inking has become a vital component of sustainable practices. Daplyn explained that while ink is essential for branding, safety, and regulatory compliance during a product’s lifecycle, it must be removable post-use to enable high-quality recycling.
Sun Chemical has developed “washable inks” specifically designed for optimal removability during recycling, particularly for plastics. Daplyn emphasized that different substrates require tailored recycling methods, and ink formulations must produce filterable, non-bleeding particles during caustic washes to ensure clean flake and minimize contamination. This approach is critical for maintaining the quality of recycled materials and supporting circularity.
Digital Labels: When Retention is Key
Interestingly, de-inking is not always the objective. In the case of label recycling for PET bottles, current U.S. and EU regulations mandate that ink remain fixed on the label during the wash process to avoid contaminating the bottle’s plastic. Here, the ink’s ability to stay adhered to the label is crucial for ensuring the recyclability of the underlying material. This highlights the need for ink formulations that can adapt to specific recycling requirements, depending on the substrate and application.
Innovation and the Path Forward
Daplyn concluded by emphasizing the rapid pace of innovation in the industry, which is driving progress toward greater sustainability. He highlighted advancements such as biobased materials, de-inking primers, new UV monomers, and substrate-specific formulations—all aimed at extending the life of materials and reducing waste.
“We have the technology,” Daplyn stated, “Now it’s about evolving our thinking. The more we can design for recyclability and removability, the closer we get to true packaging circularity.”
Key Takeaways
- Digital Print’s Advantages: Digital print is no longer too slow or costly. It offers speed, cost efficiency, and agility, making it ideal for shorter runs, versioning, and personalisation.
- De-Inking: Essential for recycling, de-inking requires inks designed for removability, ensuring clean recycling and minimal contamination.
- Label Recycling: In some cases, ink retention is necessary to prevent contamination, highlighting the need for adaptable ink formulations.
- Innovation: Ongoing advancements in materials and technologies are paving the way for more sustainable and circular packaging solutions.
Daplyn’s presentation underscored the importance of collaboration, innovation, and a shift in mindset to achieve true packaging circularity. By addressing technical challenges and leveraging digital print’s strengths, the industry can move closer to a sustainable future.
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