Toray Industries, Inc., Dow Inc., Comexi Group Industries, S.A.U., Sakata Inx Corporation, and SGK Japan (Schawk Japan K.K.) have collaboratively developed a revolutionary surface printing mono-material film packaging technology.
This innovation aligns with the European Union’s Packaging and Packaging Waste Regulation, aimed at fostering a low-carbon, circular global economy. The new material is versatile, suitable for a broad range of food and daily necessity applications.
Flexible film substrates, widely used in food packaging and detergent refill pouches, are favored for their lightness, transparency, and ease of processing. With the global population increasing, the demand for film packaging is expected to grow by 4% to 5% annually from the 2023 level of 33 million metric tons (see source 1). However, many current film packaging materials are difficult to recycle due to their multi-material composition, which meets various functional and design requirements.
To address this issue, the European Union mandates that all packaging materials be designed for recyclability by 2030. In April 2024, the European Parliament adopted the new Packaging and Packaging Waste Regulation to reduce packaging waste and enhance sustainability. This legislation requires plastic packaging to meet recyclability criteria, in line with proposals from industry bodies like Recyclass. The specifics will be defined in upcoming CEN standards, but generally, packaging must predominantly use a single polymeric material, minimizing other polymers and additives that hinder recycling.
In response to these regulations, Toray, Dow, Comexi, Sakata Inx, and SGK JAPAN have developed a surface-printed mono-material film packaging technology. This innovation reduces plastic consumption, significantly lowers CO2 emissions from printing processes, and adheres to recyclability recommendations. It also promises cost reductions and shorter delivery times due to streamlined manufacturing processes.
Toray contributed its RESOLUCIA™ flexographic plate for film packaging printing, which uses water instead of organic solvents in the development process, ensuring high print quality. Dow provided a polyethylene film suitable for surface printing, incorporating a thin gas barrier layer and high-performance materials like INNATE™ and AFFINITY™ resins for durability and sealing. Sakata Inx supplied electron beam flexo inks and varnishes, utilized on a Comexi electron beam flexo press, known for its productivity and ease of use. The packaging design focuses on surface printing, reducing the number of film layers. SGK Japan optimized the design to minimize ink usage while maintaining high aesthetic quality.
By leveraging advanced printing technology, these companies aim to standardize film packaging for food and daily necessities, reducing the environmental footprint of the industry and promoting a sustainable economy.
Samples of this innovative film packaging technology will be exhibited at DRUPA 2024, the world’s largest printing exhibition, in Düsseldorf, Germany, from May 28 to June 7.
Sources
- The future of global flexible packaging to 2028, published by Smithers
- European Parliament press release: New EU rules to reduce, reuse, and recycle packaging
Glossary
- Mono-material: Film packaging material made up to nearly 95% from a single material, simplifying recycling by eliminating the need to separate components.
- Electron beam cured printing technology: Curing printed ink with electron beam irradiation, eliminating thermal drying, saving energy, and reducing CO2 emissions.
- Flexographic printing: A letterpress adaptation using resin or rubber plates, suitable for printing on uneven surfaces like cardboard and flexible packaging.
- RecyClass: An initiative promoting plastic packaging recyclability. Detailed information: RecyClass
Corporate Profiles
Toray Industries, Inc.
- Headquarters: 1-1, Nihonbashi-Muromachi 2-chome, Chuo-ku, Tokyo
- Established: January 1926
- President: Mitsuo Ohya
- Main businesses: Fibers and textiles, performance chemicals, carbon fiber composites, environment and engineering, life sciences
Dow Inc.
- Headquarters: 2211 H.H. Dow Way Midland, MI, U.S.A.
- Established: 1897
- CEO: Jim Fitterling
- Main businesses: Innovative materials including polymers and industrial intermediates
Comexi Group Industries, S.A.U.
- Headquarters: Polígon Industrial de Girona Avinguda Mas Pins, 135 E-17457 Riudellots de la Selva. Girona. Spain.
- Established: 1954
- President: Manel Xifra
- Main businesses: Flexible packaging printing presses, laminators, and slitters
Sakata Inx Corporation
- Headquarters: 1-23-37, Edobori, Nishi-ku, Osaka
- Established: 1896
- President: Yoshiaki Ueno
- Main businesses: Printing inks, auxiliary agents, functional materials
SGK Japan (Schawk Japan K.K.)
- Headquarters: 4F IK Building, 2-24-9 Kami-Osaki, Shinagawa-ku, Tokyo
- Established: 1999
- Managing Director: Reiko Nakamura
- Main businesses: Brand consulting, creative design, localization, printing production, color management, workflow consulting, project management, user interface, and experience design
