Siegwerk's low migration inks for food packaging – safe and sustainable solutions

What developments are you making in low-migration inks for food packaging applications?

We are currently working on food packing through our specialised series known as the NPS system. Our main focus is on compliance, particularly electrical compliance. We have two categories: the NPS series and the non-NPS series. We ensure that all compliance standards are met and strive to exceed these requirements in our products. Additionally, we are committed to continuous development and improvement.

Is there any new information regarding products and their allocation?

We are excited to announce the launch of our dual-core LED technology, which features low migration. First and foremost, we are proud to manufacture our LED products locally. Our comprehensive range includes not only the ink processes and bases but also varnishes. This is a key focus area for our team of experts, particularly in the LED and low-migration segments. Additionally, we offer a complete range of varnishing solutions to meet your needs.

Is this range affordable?

Aside from varnish, all other options are in the affordable range, and the varnish itself is also included in that range. However, the issue is that the consumption of varnish is significantly higher than it should be. This means that if you have a delta (difference), your total packaging impact will be greater. As a result, this is influencing current trends in the industry.

People are increasingly opting for LED inks, with varnish being used as the final station, often in conjunction with UV inks. However, the delta for these inks is gradually closing. Two years ago, the difference between LED and UV inks was much larger, but it is now narrowing because there is a growing demand for LED inks.

So what is the norm right now for delta?

Delta is around 10%, with a maximum of 10 to 15%. As people begin using more LED varnish, that cost will definitely come down.

Is LED popular among your customers?

All our customers who have switched to LED lighting have continued to use it. However, they still face a challenge with their reliance on UV lighting. While the ink they are using is compatible, cost remains a significant factor. Currently, out of ten stations, eight are using LED, while the last station, which is responsible for curing, is still using UV. We are also working on addressing the cost issue, but we understand that cost is often influenced by demand and production volumes.

When discussing LED inks and consumables for narrow-web flexo, are there any differences compared to offset, or are the stories similar?

The same story applies to the offset side, including the ink and varnish. The varnish side remains a challenge because, in general, for every kilogram of ink used, varnish consumption tends to be 1.5 times that amount. This creates a significant difference, which has a considerable impact on the converter. Consequently, the decision not to shift the varnish means that for every kilogram of ink used, an additional half kilogram of varnish is needed, particularly in the context of opting for LED varnish.

How are you addressing the demand for inks compatible with a wider range of sustainable substrates?

In narrow web applications, the variety of substrates used is relatively limited compared to flexible packaging. However, we offer a comprehensive range of options suitable for all types of substrates in narrow web applications, without being restricted to any specific substrate.

Currently, in India, our team is not yet in place, but we are showcasing developments in this area. We have solutions and options available, including recyclable substrates. Our technology ensures that the ink can be completely removed, allowing for effective recycling of the substrate.

Additionally, we are collaborating with one or two partners for the conversion process. While we are prepared to disclose the names of these partners, we must keep that information confidential for the time being.

So it's like a beta type?

It's currently a trial phase, similar to a beta version. I'll refer to it as a trial type because, for them, their end customer has initiated the project. This makes it difficult to disclose details publicly if I recall correctly. Newspaper printers are looking into some possibilities, but we are not involved with the newspaper aspect.

At this point, I don't think they have achieved success, but we are observing progress. Additionally, we have a series called "Circuits," which essentially acts as a barrier. The idea is that it can be removed before it interacts with the substrate, allowing for a clean substrate. While this is not a live demonstration, it provides a good understanding of the process and how it works.

Is there a rebalancing of the portfolio towards UV water-based or solvent-based options based on trends? 

First of all, let’s focus on solving it based on narrow waves. In the context of narrow waves, we are equally strong in various sectors, whether it's UV or working with butterflies. This sets us apart from other companies that tend to concentrate on one specific area. We have a diverse range of applications and customers, including those in letterpress, UV, and LED. This broad distribution of expertise contributes to our high market presence and market share. Unlike some competitors who focus solely on UV, we have a complete portfolio that covers all applicable LED technologies.

Does implementing ECG impact margins on special Pantone colours?

Regarding the ECG market in India, it has started gaining attention, but the growth is slow. Currently, only one or two converters are actively working with ECG technology.

What about the electronic beam (EB) for curing? I believe UFlex is involved in this.

It seems that people are generally moving toward LED technology. Currently, it's becoming the standard, and I believe that in the coming days, this shift will only continue. Two years ago, we held a webinar where we invited all our converters to discuss the benefits of LED lighting, but participation was less than 20%.

Now, after two years, we see that LED is no longer just a trend; it has become a preferred choice. Many new investments are leaning towards LED, as people have recognised the benefits it offers. This aligns with our initial theory that LED would gain more traction over time.

Next, what do you recommend for long-lasting and durable labels, particularly in the cosmetics and personal care sectors?

We have a specific series focused on our strengths in farmhouse products and cosmetics. In the cosmetics sector, we're observing a shift towards more limited offerings. In this context, we are also analysing the market here. As a result, we have developed a different series tailored for these trends.

How do you ensure your inks maintain colour accuracy and adhesion across various materials, particularly high-end films and paper?

First of all, everything we supply to the market undergoes thorough market validation. Whenever we offer any of our products, they have already been lab-validated. We do not introduce anything to the market without this validation process. Whether it involves high-end applications or substrates, all our products are rigorously tested in the lab.

Additionally, we have all the necessary equipment to ensure that our products meet the required standards for curing, adhesion, and other performance criteria.

Is the lab validation conducted in-house?

Everything is handled in-house. As a global company, we also have global support. If a particular service or product is not available in India, we can access support from Asia or other global locations. We typically do not use third-party labs, unless a customer specifically requests certification from one. Otherwise, we handle everything internally.

Is there anything else you would like to share with our readers?

One important aspect of the Expo is that we're not just showcasing our product; we recognise that simply providing the product won't solve the colour-matching problem for converters. We're focusing on how we can support them with services. For example, through our Fast Match system, we aim to assist them in efficiently matching colours. Currently, colour matching relies heavily on the specialised knowledge of the individual performing the task. If that person is not available, it creates challenges for the converter.

Our Fast Match solution is designed to automate and streamline the manual colour matching process, and it is now cloud-based. Additionally, we are collaborating with many of our converters to encourage them to adopt our Ink Kitchen system. This system helps reduce costs associated with excessive ink waste, which is a significant inefficiency in the industry. By promoting the use of Ink Kitchen, we are contributing to sustainability and environmental stewardship by minimising ink wastage.

Furthermore, we have introduced a digital imaging system that provides clear visibility of returned ink quantities, helping converters make better use of returned ink. Our focus is on improving these processes and supporting our partners in achieving greater efficiency.

What is the difference in distance between digital ink kitchens and conventional ink kitchens?

There is a general tendency to use whatever tools or materials we come across first. This often means that older resources remain unused. However, the digital system can guide you to the best ink options to use, enhancing your ability to manage your team effectively.

The system is not solely dependent on individual efforts; it provides support for better management. Additionally, there is a complete dashboard available that allows you to track your ink usage and monitor precision over time. This digital platform helps manage manual tasks efficiently.

We are currently promoting this system to our customers. It is designed to facilitate seamless data transfer and faster ink matching. We are also in the initial stages of collecting statistics about its usage. However, for now, it is primarily focused on our current clients.