But the ink formulation and its performance should never vary – and once you are on-press, the ink should deliver exactly what is set up to do. No batch to batch colour variation and same press performance as has been set in specification. When it comes to the new and more demanding area of narrow-web food label and packaging print market Flint Group thinks that it has found the answer: its new Flexocure Ancora UV flexo ink, specially formulated for food labels and packaging.
 

In response to new demands in food label and packaging, Flint Group introduced this ink series, in April 2011.  
 

All types of UV inks consist of a range of different ingredients, with the photoinitiators and monomers commonly used being considered as potential migrating substances. When formulating a true low migration ink, such as Flexocure Ancora – you have to use a fine selection of special monomers, binders and photoinitiators that have excellent cure performance as well as of high molecular nature that they will not migrate through common packaging and label substrates.
 

Upal Roy, managing director of Flint Group India, says, “When formulating true high performance UV inks for food labels and packaging – such as Flexocure Ancora – special care in formulation is required to be able to find an optimal combination of excellent press performance and still being able to produce an ink that meets the stringent requirements of the food packaging industry.”

 

Migration test

Roy says, “We have been working hard on this development for some time and are very pleased with the results. To be able to offer a UV Flexo ink with high performance on press, excellent colour strength and adhesion while still meeting lowest possible migration limits, is exactly what our clients have been looking for – which is, no compromise in performance due to low migration properties.”
 

Commenting on the migration studies Roy says, “For this new ink series we have conducted migration tests at several independent institutes, as well as in our own analytical laboratories. The migration measurements have indicated that when correctly applied on suitable packaging structures migration levels with Flexocure Ancora are below currently accepted limits. This was verified based on the standard migration test method using the food simulants 95% ethanol and tenax as set out in Commission Directive 97/48/EC. Furthermore, we have the confirmation of leading end-users that the ingredients used in Flexocure Ancora are meeting their company guidelines.”
 

A variety of applications

Flexocure Ancora is suitable for a wide variety of applications. This includes self-adhesive labels, coated and uncoated papers, PE, top coated PE and PP, PP, cast coated papers and PVC, wrap around labels, in-mould labels (BOPP), unsupported film applications and sleeves.

Roy says, “All analytical results have been confirmed by printers who applied Flexocure Ancora on actual final packaging constructions: The migration limits are below stipulated limits. Looking at all the tests and the practical results with Flexocure Ancora we can say that this ink series offers a unique combination of low migration and high performance for UV flexo printing in the food segment.”

  

Impact of raw material cost

Flexocure Ancora is a premium product ensuring top class performance and that stringent requirements are met. Roy is very clear about the fact that the exceptional performance profile of the ink series comes with extra cost. How much extra, Roy is reluctant to say: “The raw materials that are required to ensure an intrinsic low migration profile today still come with high cost in the market place. Conscious of the challenges our customers face, we optimised the cost of the formulations. However we did not want to compromise on the favourable migration profile that makes this ink series stand out in the market-place. Also the ink provides the performance that is required to be able to offer premium print services to brand owners. Hence we had to ensure that this ink series is avilable with a higher market price than conventional UV inks.”

Roy is quite clear about one thing: ”End-users in the packaging area require this type of technology. Today, it is a well-known fact that the ink cost is a relative small portion of the total cost of a packaging construction. As food safety is a primary concern, it is imperative to select the right type of food-grade inks.”

 

New ink plant

Besides announcing developments in UV flexo technology, Flint Group India has set-up a new manufacturing plant in Gujarat. With a growing packaging industry in India, Flint Group hopes to cater to customers in this market. 
 

Roy says, “We have an ISO 9001-2000 certified mother plant for packaging inks in Bengaluru and blending units in Hosur and Noida supported by depots at Pondicherry, Kolkata, Hyderabad and Navi Mumbai.”
 

Roy added, “We are proud to be in a position to support the market even further with our new plant in Lamdapura, Savli.” This plant is located very close to our existing mother plant for Newsink at Savli (near Vadodra). 
 

The ink manufacturer which was experiencing a space crunch at its mother plant in Bengaluru, decided to invest in larger property to build a new plant. The plant which is fully operational has been built and has met European standards on processes and safety. It has separate areas for the manufacturing of water-based, toluene-based and toluene-free solvent-based inks.

 

Main benefits

When introducing a high performance ink type such as Flexocure Ancora – was questioned by the print community. But as per their survey, Flint Group has found that printers purchase “on price per kilo” – and this lulls them into a false sense of costing, in the long run. 
 

Roy clarifies, “Yes, our inks may be higher in cost per kilo, but we know that our inks give more value to the bottomline of a printer as there are many other advantages. It is important to understand that inks with higher colour strength can be used both as delivering outstanding shelf appeal, making clients’ printed product stand out better on the shelves”. Roy feels, the ink will deliver better mileage, and can print more labels per kilo of ink. 
 

Roy says, “A 10-15% colour strength difference, impacts the cost of the labels. Also press-ready and press stable inks give you guaranteed press consistency – your products are always meeting the highest standards – meaning that presses will run much more efficiently over the course of the day, and week – saving you press time and money. Remember that the printing press is the most expensive part of producing labels and packaging, and every hour that your press is not running is costing much more than a kilo of ink will...” 
 

Of course in case of Flexocure Ancora another argument with the biggest factor for its use is, food safety. When printing labels for food packaging, low migration inks are without alternative, especially when printing for renowned brands and brand owners. The new Flexocure Ancora inks might not be for everyone, but for this specific type of printer they are intended to answer the prayers of the creme da le creme of India’s high end label printers who are interested in a pedigree product. 
 

Roy is keen to emphasise that it depends on what a printer want out of the inks. To perform at the best, the ink calls for supporting technology.
 

Roy concludes, “Printers that have invested heavily in a fast press want an ink that can bring out the best in it. There is a strong case for using Flexocure Ancora if you are that kind of printer, because the return on investment – in terms of hitting your colour standards, consistently, with cleaner, sharper colours – is quick and unarguable. With Flexocure Ancora the printer can further experience the peace of mind coming with the knowledge that their customers can rely on food safety being respected in all their printed products”.

Technical Specification

Speed  up to 150 m/min

Mileagei cm³/m²  Process: 3-4, Solids: 5-10

Printability Process: suitable, Solids: suitable

Material suitability  Paper, thermal substrates, plastic substrates

Application suitability PS labels, wrap around labels, flexible Packaging

Contact  M Rajnarayanan Flint Group India +91 80 27832420 +91 9845123955 m.rajnarayanan@flintgrp.com www.flintgrp.com