德國Siegwerk研發去除包裝印刷油墨的技術

撰文者: 塑膠智庫 | 出刊日期:2023-02-08 | 文章編號:PJ44XU5BJW


隨著脫墨(Deinking)和脫層(Delamination)底漆的發展,德國印刷公司Siegwerk希望為塑膠包裝材料的回收創造一個機會,這項專有技術能夠分離複雜的積層包裝(Laminated Packaging)結構,並去除油墨和清漆,以產生可以在許多應用領域使用的高品質再利用回收物。


專有技術可以促進回收

Siegwerk專有的技術可以作為促進回收的關鍵,將這些脫層底漆技術用在包裝結構,使其能夠透過再循環流中使用的「熱洗滌步驟」,將積層結構分離成它們各自的膜層。另外,底漆有助於使印刷薄膜脫墨,以確保無色薄膜層可以立即重複用於生產新的高品質塑膠材料,此外,如果不需要脫層步驟(如已經優化的單層包裝結構),此公司還提供一種可以簡化脫墨步驟的技術。


使用一種可在現有塑膠回收流中回收的薄膜層較佳

使塑膠包裝適合循環方法的主要挑戰是在不損害包裝主要目的的情況下,讓高科技包裝材料結構的複雜性(在最佳情況下)適應現有的回收流:在足夠長的時間內保持包裝內容的新鮮。另外,關鍵是僅使用一種塑膠材料,甚至最好僅使用一種可在現有塑膠回收流中回收的薄膜層。在許多工業化國家中,僅使用聚乙烯(Polyethylene)或聚丙烯(Polypropylene)作為包裝材料(對於最終用途而言,其功能是可接受的),因為相對應的回收基礎設施已經到位,因此效果很好。


脫層底漆技術提供一種解決方案,可為複雜包裝結構創造可回收性

這項新的底漆技術可以獲得高品質的再生材料,進而大大減少對新塑膠材料的需求,也減少對有限資源的使用。這是使塑膠廢棄物具有經濟價值的關鍵,並避免垃圾進入掩埋場。儘管始終建議盡可能將材料結構簡化為單一材料,但脫層底漆技術提供一種解決方案,可為複雜包裝結構創造可回收性。

參考資料

With the development of a deinking and delamination primer, Siegwerk hopes to open the door to the next level of serious recycling for plastic packaging material. This proprietary technology enables the separation of complex laminated packaging structures combined with the removal of inks and varnishes with the goal of yielding high-quality recyclates ready to be reused in many applications.
In this Innovation Spotlight, Stefan Häp, head of technology and innovation brand owner collaboration at Siegwerk, s to us why this is a key lever to integrate plastic packaging materials further towards a circular economy.
We already need three planets to meet today’s consumption patterns in the developed world. That’s why recyclability plays an integral role in future packaging designs and structures with regard to the sustainable use of resources. Keeping materials in closed cycles minimizes waste and avoids leakage that causes ecological and economic harm.
Packaging needs to be rethought to design out waste and pollution right from the beginning and regenerate natural s. These are the principles of the so-called circular economy, a new economic approach that already became a relevant management model for most FMCG brand owners within recent years.
In parallel, plastic packaging became incredibly complex within the last decades to continuously increase performance, reduce weight and, particularly, costs. Today, modern flexible plastic packaging often consists of several layers of different plastic types, decorated with bright and colorful inks and glued together for eternity. A big challenge for any recycling efforts.
So, the major challenge in making plastic packaging fit for a circular approach is to adapt the complexity of high tech packaging material structures to - in the best case - existing recycling streams without compromising the main purpose of the package: keeping content fresh and consumable for a sufficiently long time.
The key is the use of only one plastic material type, preferably even just one film layer recyclable in existing plastic recycling streams. Using, for example, only polyethylene or polypropylene as packaging material, where the functionality is acceptable for the end-use, works well in many industrialized countries as the corresponding recycling infrastructure is already in place.
However, the plastic recycling industry is neither an NGO nor self-sustaining. To avoid an ecologically undesirable landfill or the incineration of plastic packaging (questionably called ′thermal recycling′), serious recycling needs to pay off sufficiently for all stakeholders.
Besides, using EPR fees to counter the ecological consequences of non-recycled materials the composition of the packaging material remains decisive for using the recycled materials in a meaningful way. To do so, recyclates have to be as clean as possible.
Good quality recyclates require a separation of laminated materials their individual film components and the removal of any coating like inks, varnishes, and adhesives to yield raw materials that are suitable for a reasonable reuse.
Here, the proprietary deinking and delamination primer technology from Siegwerk can serve as a key lever to facilitate recycling. Implementing these delamination primers a packaging structure enables the separation of laminated structures their individual film layers by using a so-called ′hot washing step′ in the recycling stream. In addition, the primer facilitates a deinking of the printed films to ensure a colorless film layer that can be instantly reused for producing new high-quality plastic materials.
If a delamination step is not required e.g. for already optimized monolayer packaging structures, the company also offers a technology that facilitates the deinking step likewise.
This new primer technology helps to significantly reduce the need for new plastic material and thus the use of finite resources by giving access to high-quality recycled material. This is a key lever to give plastic waste an economical value that allows serious recycling and avoids problematic landfill and so-called thermal recycling.
While it is always recommended to simplify material structures towards mono-materials where possible, the delamination primer technology provides a solution to improve the recyclability of multi-material packaging structures that are needed to deliver high functionality for complex packaging requirements. and enable packaging circularity in terms of a circular economy.

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Werner & Mertz, in cooperation with its Reyclate Initiative partners, pioneered a new printing ink for applications way beyond its industry.
With the ink manufacturer Siegwerk Druckfarben AG & Co. KGaA, the EPEA Switzerland GmbH (Environmental Protection Encouragement Agency), and the global packaging and paper company Mondi, the Mainz cleaning products maker has developed a recyclable printing ink for flexography which has been awarded Material Health Certification (MHC) GOLD.
The use of sustainable printing inks is a significant step in designing packaging according to the Cradle-to-Cradle principle.
′In the spirit of the Open Innovation approach promoted by the Werner & Mertz Recyclate Initiative, the certified ink series with the product name ′NC 270′ is not patented. It may be and should be used by other companies,′ said Torsten Haas, packaging developer at Werner & Mertz.
Within the Recyclate Initiative, all packaging is developed per the Cradle-to-Cradle principle, that is, designed from the start to go a closed material cycle and to pose no risk to human health and the environment.
Sustainable and healthy raw materials are just as important as packaging′s recyclability after its use phase.
That′s why, in addition to the bottles and caps made of recyclates, sustainable printing inks are critical for a product′s recyclability.
With the Material Health Certification, the safety of the solvent-based printing ink NC 270 is now confirmed scientifically for biological cycles. Gold certification is awarded exclusively to products that ′do not contain carcinogens, mutagens or reproductive toxicants with plausible exposure routes,′ according to the MHC.
′The New Green Deal of the EU Commission calls for safe and reliable plastic packaging that is sustainable for coming generations and the environment. This project is the guide to that goal. It has been confirmed by an independent third-party with the only certification for cycles,′ said Albin Kälin, CEO of EPEA Switzerland, an accredited assessment body for Cradle-to-Cradle Certified and MHC Standard.
In 2017 Werner & Mertz, Siegwerk and EPEA Switzerland developed a sustainable UV ink for offset printing as many pigments used in the standard process did not comply with the Cradle to Cradle Certified requirements for certification.
The developed UV offset printing ink series, which also received MHC GOLD status, is used for the labels of the Frosch brand Citrus Shower & Bath cleaner.
With the ink series NC 270 for flexographic printing, the Werner & Mertz Recyclate Initiative has developed the second important printing process for packaging.
The flexographic printing ink can be used to print polyolefin plastic sheeting such as polethylene and polyproplylene. It also is well suited to the stability and resistance properties required for the stand-up pouch.
′We are proud that we could contribute an element to the development in this outstanding groundbreaking project. Now that a solvent-based ink for flexographic printing with MHC Gold certification is available, many 100 percent recyclable packaging solutions based on this single-layer PE stand-up pouch can be realized for the food and non-food sectors,′ said Dr. Stefan Häp, Brand Owner Collaboration Team at Siegwerk.
The idea for a sustainable flexographic ink came up in the joint development project with Mondi for a completely recyclable stand-up pouch (StripPouch).
Honored with the German Packaging Award and the World Star Award, the project yielded the first pouch, which, thanks to the monomaterial and removable printed panels, can be recycled at a high quality level.
The independent Institute Interseroh said in its assessment that the stand-up pouch has ′very good recyclability that cannot be optimized any further.′
Having d optimum conditions for the technical cycle, Werner & Mertz and Mondi wanted to do the same for the biological cycle.
Because Mondi uses only flexographic printing for the StripPouch, the cooperation partners from 2017 came together again and drew on their earlier work to develop sustainable printing inks for yet another printing .
′The joint project on the development of the StripPouch was such a success because everyone involved pulled together from the very beginning. With the use of sustainable and certified printing inks, we are taking another big step together toward the circular economy and packaging solutions that are designed with sustainability in mind,′ said Jens Kösters, manager of Technical Services at Mondi Halle, Werk Steinfeld.
By the end of 2020 the new Siegwerk NC 270 printing inks will be used in series production of the first stand-up pouch for creme soap for the Frosch Senses brand.

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