Flexo Case Analysis (1)

Case 1: Replacement of Harmful Materials in the Flexible Web Printing Process for Wide Webs A wide-web web flex printing company uses flexible plastic substrates (eg, plastic bags for bread) to make flexible, folded packages. Original solvent-based inks were replaced with new water-based inks. The purpose of this case is to evaluate the feasibility of this replacement process, economic benefits, and changes in VOC emissions. The technical and technical evaluation is to determine the reduction of harmful substances that are volatile and liquid phase solids. From the use of solvent-based ink to the use of water-based ink to greatly reduce the VOC emitted, this process requires the improvement of several equipment, raw materials also have to do a corresponding replacement, including drying device performance improvements, impression cylinder Modifications, ink system upgrades, plus an on-line corona treatment system. Water-based inks containing less than 72.5% VOC replace conventional solvent-based inks, or a combination of both. For every percentage point increase in the use of water-based inks, VOC radiation is reduced by 14 pounds (1b). The data for this cultivator was based on the use of solvent-based ink 22501b on a weekly basis, resulting in a VOC of approximately 15701b. Usually this substitution will not have a negative impact on product quality, nor will it produce non-toxic waste. After the ink was replaced, the operating steps were improved and the employees were trained. The liquid F003 waste from the waste ink and cleaning solvent was found to have been reduced by an average of 95%. Economic assessment is assessed by calculating the cost of retrofitting printing equipment, adding auxiliary equipment, waste disposal, inks and solvents. A net investment of $39,165 is required to complete this innovation plan. If 21% of water-based ink is used for replacement, the cost recovery period will be two and a half years, and if 100% water-based ink is used, the recovery time will only be 0.54 years. The use of water-based inks to replace the benefits of solvent-based inks to reduce VOC radiation and liquid hazardous waste also brings additional benefits, including reducing indoor air pollution and reducing the disposal of hazardous solvents. Workers are consciously working hard. Further reduce waste generation. Case Study 2 Successful U.S. Industries in Reducing Resources and Recycling Amko Plastics, Cincinnati, OH, is a printing company that provides packaging products to customers, and is involved in the packaging of retail merchandise and industrial products, with approximately 280 people. By converting from solvent-based inks to water-based inks, they have minimized the amount of their volatile volatile matter by approximately 88%. The reduction of alcohol solvent vapor has greatly improved the air quality of the printing shop. Some of the following process improvements and corrections have been evaluated and implemented: • Control of ink pH to maintain ink viscosity and print quality. • Improve the drying head between several consecutive color groups on the press to allow the heated air to adhere to the film (increasing the drying capacity of the water-based ink). · Redesign ink metering system to handle high strength inks and thinners. • Replace metal anilox rollers with more expensive ceramic rollers, which can greatly increase its service life. Replace the surface material of the dampening roller with a harder rubber to increase the service life of the ceramic anilox roller. • Change the lubricant content in the turpentine in the system and equipment so that the film can be easily ejected for high-speed printing. • Install a large corona treatment system to remove static electricity from the film surface and increase the surface tension on the film surface to allow easier adsorption of water-based inks. • Replace the traditional "gel back" with a foam backed "glue back" to get additional pressure on the water-based ink. Amko's current yield and quality gains are comparable to other solvent-based ink prints in the United States. Case 3 Venture Packaging Venture Packaging is working on the replacement of solvent-based inks, coatings, and adhesives with water-based materials to reduce emissions and the amount of flammable waste generated. The project began in 1980 and the emission of exhaust gas has been reduced by approximately 55%. With the further use of water-based materials, it is also possible to reduce it further by 15% to 20%. This has achieved the greatest success in adhesives. Water-based adhesives are now used in almost all products. The development of ink is more difficult because it varies from substrate to substrate. Capital investment has been reduced to a minimum, but the cost of experience has increased. In addition, the incinerator that can be added also requires a large amount of money. Case 4 FC Meyer's waste in water and ink reduces the use of hazardous products Case study FC Meyer is a carton manufacturing and printing company with 200 employees and eight printing presses that perform about three shifts per day five days a week. system. In 1989, FC Meyer implemented the conversion from solvent-based inks to water-based inks, reducing the VOC emissions from the previous 280 tons per year to less than 10001bs per year, and the production quality has not changed, and the traditional work pressure is greatly increased. Decrease. In 1992, they began to look for ways to further reduce waste in the cleaning process. Through the training and cleaning operations of the company's employees, the company reduced its previous 10 barrels of hazardous waste emissions to 2 barrels of non-hazardous waste! These reductions are achieved by collecting as much ink as possible before flushing and minimizing the amount of water used. In order to reduce the amount of clean water, the company recycled the waste water and poured it into the black ink to have a significant effect on the color quality of the ink. Used water can also be added to other colors, such as gray, and its amount is less than that used in black ink. The solids in the wastewater have been reduced from the previous 30% to 13%. So the amount of water used has also been reduced by 35%; now washing a press requires only a pint of water. Through the recycling of water, waste disposal has also been reduced from the previous 10 barrels per week to 2.55 gallons.