Driving sustainability in printing: How digital technology can reduce waste and carbon footprint

In the landscape of flexographic printing, the traditional ‘forecast demand’ model has long been regarded as the most cost-effective approach for high-volume, established SKUs. However, as Michael Matthews, product manager at Domino, highlights, “the shift in consumer behaviour towards limited product runs, particularly for seasonal and promotional releases, has changed the game.” This shift has left converters facing unpredictable packaging volumes, as brands opt for smaller quantities to reduce waste during the product testing phase.

Matthews explains, “Managing these shorter print runs presents significant challenges for flexo converters, particularly with the costs associated with creating printing plates, the time-consuming nature of press setup, and the waste generated during the setup process.”

To navigate these challenges, converters might consider enhancing their capabilities by integrating digital printing options with their flexo presses, effectively creating a hybrid line. Alternatively, investing in a digital roll-to-roll press alongside existing flexo operations can enable converters to adopt a more sustainable ‘print-on-demand’ business model tailored for shorter-run packaging.

Digital printing for sustainability
In today’s market, digital printing technology is revolutionising the way converters approach their work. With digital printing technology, utilised in roll-to-roll or as part of a hybrid printing process, converters can present a completely new business model to their brand customers. This approach allows for short-run or variable product packaging, effectively cutting costs and reducing waste. As Matthews points out, “The shift towards digital printing offers brands the flexibility they need to respond to market demands while also prioritising sustainability.”

Reducing avoidable print waste saves money for both converters and brands and diminishes the necessity for managing excess printed stock. Matthews emphasises, “Every piece of excess stock represents not just a financial cost, but also a significant environmental impact.” The energy consumed during the transport and recycling of surplus stock adds to a brand’s overall carbon emissions, making it imperative to consider smart printing practices.

Moreover, large volumes of water and chemicals are frequently required to de-ink surplus stock for recycling, posing a pollution risk if handled improperly. As Matthews asserts, “Sustainable practices in printing not only benefit the bottom line but also protect our environment for future generations.” By adopting digital solutions, companies can take significant steps toward a more sustainable future.

Opportunities for environmental impact
Print waste goes beyond merely discarding printed packaging due to overstock and obsolescence. "In today's market, the focus should be on minimising waste at every stage of the printing process," says Matthews. Digital printing technology presents converters with various opportunities to lower their environmental impact, particularly when it comes to improving the performance of flexographic processes in a hybrid setting.

Print-on-demand allows for the elimination of minimum order quantities, effectively preventing overruns. "This not only saves energy but also reduces ink and substrate usage, along with decreasing the need for transporting and recycling excess stock," explains Matthews. This method can greatly contribute to more sustainable practices in the printing industry.

With late-stage customisation, manufacturers add finishing touches to pre-printed stock right at their facilities. "This approach allows converters to print packaging designs in bulk, while still having the flexibility to make updates to promotional content or variable data just before or during the packaging process," Matthews notes. As a result, there is a reduction in obsolescence, further enhancing sustainability.

The costs associated with plates and analogue pre-press waste can be significant, sometimes accounting for over 10% of a brand's annual spending, depending on the number of SKUs produced. "By reducing or even eliminating the need for plates, we minimise not just water consumption and ink waste, but also chemical waste during the cleaning process," says Matthews. This, in turn, reduces the need to treat contaminated wastewater, making a considerable difference to environmental impact.

Matthews highlights that "the precise drop placement provided by digital inkjet printheads enables these presses to use only the necessary amount of ink for a label design." This eliminates residual ink waste seen in analogue plates during job changeovers. Furthermore, onboard automation for maintenance tasks such as printhead cleaning and consistent ink circulation ensures reliable performance while reducing overall consumables use. The high-efficiency drying technology in modern digital inkjet label and corrugated presses also typically uses fewer pinning and curing lamps than flexo processes, resulting in additional energy savings.

Digital printing streamlines the pre-press workflow through automation via digital front-end software, allowing for digital proofing and cutting down on waste from hard proofs. Matthews states, "Real-time inline RIP capabilities onboard digital presses maximise utilisation, which reduces energy consumption during idle periods and lessens the environmental impact of each print." Additionally, automatically monitoring and adjusting production patterns helps converters save time, improve operational efficiency, and reduce print waste, ultimately decreasing the overall sustainability footprint.

Finally, combining pre-press, printing, and finishing into a single, automated hybrid label printing process significantly lowers power consumption. "Shorter set-up times and more efficient job changeovers lead to less material waste, benefiting both the environment and the converter’s financial performance," says Matthews.

Is digital printing a key approach?
In the right circumstances, digital printing technology can significantly aid converters and their brand customers in establishing more sustainable consumption and production patterns that align with broader sustainability commitments. As Matthews emphasises, "Digital printing offers significant opportunities for limiting avoidable waste, particularly through print-on-demand business models and late-stage customisation."

Converters that are transitioning to digital or enhancing their analogue printing processes with a digital printing module for short-to-medium runs can anticipate a reduction in waste and associated carbon emissions. This switch boosts overall efficiency and leads to cost savings that can positively influence profitability. As Matthews notes, “The ability to tailor production to actual demand is transformative and crucial for reducing environmental impact.”

With over 60% of converters planning to invest in digital technology in the next 24 months, Matthews asserts that “the time to act is now.” Embracing digital printing is not just a step towards greater efficiency; it is also a vital move towards achieving sustainability goals in a rapidly evolving industry.