drupa conference, 2012 - european- · pdf filebasf nederland b.v. e-edg printing &...

DRUPA Conference, 2012

BASF Nederland B.V. Steven Zijlstra

E-EDG Resins for Printing & Packaging 15-05-2012

BASF Nederland B.V.

E-EDG Printing & Packaging

Water-based Binders for Flexible Pkg. Inks

Agenda

1. Market information

2. Current situation on lamination inks

3. New developments on water-based lamination

4. Current situation on surface-print inks

7. Eco-efficiency

6. Conclusions

8. Questions

5. New developments on water-based s/p inks

BASF Nederland B.V.


50,349,7

4.5 0.5

95.0

solvent-based water-based UV

8.02.0

90.0

solvent-based water-based UV

Paper and Board Flexible Packaging

Water-based binders for Flexible Pkg. Inks

Market Information

Total European Liquid Ink Market

Source: BASF Internal Marketing

BASF Nederland B.V.


Compliance / Safety Performance / Effect

Cost / Efficiency

Print quality

Carbon Footprint

Colour strength Lower energy consumption

Multi purpose inks

Adhesion on flexible films

Printing speed

Resistance properties

Food contact

Lamination bond strength

Sustainable raw materials

Solvent emission control

Safety and health protection

Material saving

Resolubility

Capital investment saving

Opacity

Explosion safety

Reduced coatingweigths

Printing & Packaging – Europe

Unmet Needs / Development Drivers

http://84.244.13.1/algemeen/artikelen/img/476Euromunt.jpg

BASF Nederland B.V.


Flexible Packaging

Application Areas

Surface print PE

Low- /medium-duty

Surface print PE

Heavy-duty Surface Print OPP

Reverse Print OPP

Low-duty lamination

Flexible Packaging Application Areas

Surface print and lamination inks

Surface print

Lamination

Reverse Print OPP, PET

Medium-duty lamination

Reverse Print Nylon, PET

Heavy-duty lamination

BASF Nederland B.V.


Lamination Ink Market

Current Situation

Lamination market is currently covered for 99% by solvent-based ink

First generation water-based lamination inks

Waterbased PUD ink General purpose ink, for low-, medium-duty lamination

+ Good lamination bonstrength (OPP, PET)

- Poor compatibility with various Pigment Concentrates

- Moderate resolubility / printability (substrate wetting)

- High price

Typical solvent-based lamination inks

NC / Thermoplastic PU ink General purpose ink, for low-, medium-duty lamination

PVB / Adhesion promotor ink Medium-duty lamination ink, flexo & gravure

PVC ink Heavy-duty lamination ink, gravure only

NC / Elastomeric PU ink More universal ink, for medium-duty lamination

Elastomeric PU ink Universal lamination ink, flexo & gravure

E

V

O

L

U

T

I

O

N

BASF Nederland B.V.


Lamination Inks

Key Parameters

Adhesion to the substrate

Good Lamination bondstrength

on different substrates (OPP, PET)

before and after heatseal

with different adhesives

Blocking resistance

Printability in fulltone and halftone

Resolubility

High colour strength

Transparancy

Ink stability

Price

Print Related Properties Physical Properties

BASF Nederland B.V.


New Development Product

Resolubility

Good

Resolubility

Bad

Resolubility

Before stop

After 20 prints

After 40 prints

After 200 prints

BASF Nederland B.V.



Adhesion & Lamination Bondstrength

Ink should have good adhesion

to the substrate

Coex-OPP Polyester

A

d

h

e

s

i

o

n

A High

Bondstrength

B Low

Bondstrength

PET//LDPE laminate

5% Transf. 95% Transf.

A B A B Interaction Ink/Adhesive bondstrength

Before lamination After lamination

Lamination construction should have good

bondstrength and should not show ink

transfer

Printed PET substrate

BASF Nederland B.V.



Lamination Bondstrength

Polyester

Colour

White

Adhesive

LDPE


F

O

R

C

E

F

O

R

C

E

12µm PET

2µm Ink

2µm Adhesive

50µm LDPE No diffusion of adhesive into ink

No/Low Lamination Bondstrength

Diffusion of adhesive into ink

Good Lamination Bondstrength

Laser Confocal Scanning Microscopy:

12µm PET

1µm Ink

3µm Adhesive

50µm LDPE

Adhesive penetration into the inklayer(s) important for bondstrength

BASF Nederland B.V.



Blocking Resistance

Blocking resistance:

● In general, inks based on low Tg emulsions show

better lamination bondstrength compared to inks

based higher Tg emulsions

● Fine-tune the “softness” of the ink in relation to

the blocking resistance.

Blocking test:

5Ton/30°C/24hrs.

Blocking No blocking

Specac lab press

BASF Nederland B.V.



Final Product Properties

Rheology Controlled emulsion, for lamination applications

BASF patented novel technology platform

● Showing very good resolubility

● Showing good ink stability in combination with

various pigment concentrates in the market

● Good OPP and PET lamination bondstrength

● Blocking free

● Designed for combination water-based colours + water-based white

● Also possible: solvent-based colours + water-based white

Print trials on Development Product

BASF Nederland B.V.



Flexo Print trials

Inks were formulated

(CMYK + backing white)

Print trials done on W&H Soloflex

Print trials done at Comexi 8 colour CI press

Reverse print OPP (MB400) & PET (Mylar 813)

100% Colour, 200% Colour, with/without white

Fulltone, fine lines and fine halftones

Printspeed 200 m/min

Comexi

8 colour CI press

Good print quality and very good resolubility

Anilox and plate cleaning very easy

BASF Nederland B.V.



Lamination Trials

Printed substrate laminated on:

Nordmeccanica s/f laminator

Comexi Nexus s/f laminator

Adhesive used: 2K PUR, solventfree

Coatingweigth: 2.2 g/m2 dry

Good processing on laminator

OPP/OPP, OPP/PE, PET/PE

laminations made

After 7 and 14 days curing,

bondstrength measurements

Comexi Nexus EVO s/f laminator

BASF Nederland B.V.




Lamination bondstrength in N/15mm

Adhesive: 2K PUR solventfree, 2.2 gsm dry

Heatseal conditions: 140°C/400N/1sec.

Lamination results meet market requirements

Lamination Bondstrength (N/15mm)

Colour White OPP//OPP PET//LDPE

- Heatseal + Heatseal - Heatseal + Heatseal

Colour 3.0 3.0 2.0 2.0

White 3.0 3.0 2.5 2.5

Colour White 2.5 2.5 1.5 1.5

BASF Nederland B.V.


Surface Print Ink Market (flexible pkg.)

Current Situation

Surface print market is currently covered for 90% by solvent-based ink

First generation water-based inks for surface print (flexible pkg.)

Waterbased acrylic ink

(self crosslinking technology)

Suitable for surface print PE, for carrierbags, etc.

+ Very good resolubility, printability

+ Good physical properties on PE

+ Good general physical properties on OPP

- Insufficient heatseal resistance on OPP

- Drying speed of surface print white

Typical solvent-based surface print inks (flexible pkg.)

NC / Plasticizer General purpose ink, for low performance PE

NC / Polyamide Surface print PE, for medium / heavy duty inks

NC / Thermoplastic PU Surface print PE & OPP, for flexible packaging

E

V

O

L

U

T

I

O

N

BASF Nederland B.V.


Surface Print Inks

Key Parameters

Adhesion to the substrate

Good physical properties

scratch-, wrinkle resistance

water resistance

heatseal resistance

blocking resistance

On various substrates (PE, OPP)

Printability in fulltone and halftone

Resolubility

High colour strength / Opacity

Drying speed

Ink stability

Price

Print Related Properties Physical Properties

BASF Nederland B.V.



Flexo print trial at DFTA (F&K)

Surface Print coex-OPP (30MB400)

S/B

White

W/B

White

S/B White

+ S/B Col.

W/B White

+ S/B Col.

Printability White

(100 500 m/min)

+/- + (!) n.a. n.a.

Overprintability White n.a. n.a. std > std

Adhesion + + + +

Scratch resistance + + + +

Wrinkle resistance -dry

-wet

+

+

+

+

+

+

+

+

Heatseal resistance

(180°C) + + + +

Blocking resistance + + + +

Gloss + ++ + ++

Solvent retention std 0 std < std

Resolubility std < std n.a. n.a.

Trial design: Text & Block

BASF Nederland B.V.



Ink usage water-based vs solvent-based white

Solvent-based White Water-based White

Ink Viscosity (undiluted) DIN4 27” 23”

Ink Solids (undiluted) 48.5% 59.4%

Dilution 100:17

(EtOH/EtAc=80/20)

100:2

(Water)

Ink Viscosity (diluted) DIN4 20” 20”

Ink Solids (diluted) 41.5% 58.2%

Application Dry

Wet

1.5 g/m2

3.6 g/m2

1.5 g/m2

2.6 g/m2

Ink usage

Solvent usage

3.1 g/m2 Ink

0.5 g/m2 Solvent

2.5 g/m2 Ink

0.1 g/m2 Water

20% Less Ink Usage (less ink purchase)

No Dilution Solvent Usage (less solvent purchase)

BASF Nederland B.V.


Conclusions

New generation water-based lamination inks, showing:

Good resolubility / printability

Good lamination bondstrength on OPP and PET lamination

Good blocking resistance

New generation water-based surface print white, showing:

Good resolubility / printability

Faster drying and suitable for high speed printing

Very good visual appearance (gloss, opacity)

Very good physical properties on OPP and PE

Overprintable with both s/b or w/b colours

No solvent retention

BASF Nederland B.V.


Eco-Efficiency Analysis

Solvent-based vs Water-based printing

User Benefit:

Printing 1000m2 of

LDPE Film

40% image coverage,

4-station press,

Europe.

0.0

1.0

2.0

0.0 1.0 2.0

costs (norm.)

en

vir

on

men

tal

imp

act

(no

rm.)

Water-based

Solvent-based

BASF Nederland B.V.


Water-based binders for Flexible Pkg. Inks

drupa conference, 2012 - european- · pdf filebasf nederland b.v. e-edg printing &...

Documents