Flexographic printing facilities deal with many things that can affect the environment. Materials such as ink and solvents used in the package printing process can harm the environment and people if the company does not meet adequate standards and environmental protection procedures or if they are not properly managed. State and EU environmental regulations explain what legally can and cannot be done with post-production waste. The regulations describe how pollution (waste) should be controlled, stored, treated or disposed of. Its scale and type largely depend on the technology, raw materials and consumables, storage techniques, work organization and production size in the printing company.

Pollution prevention means doing everything we can to reduce the amount and toxicity of the pollution generated in the production process. Waste and pollution reduction is the most desirable and effective activity that every printer should consider. Preventing pollution may be something as simple as using a catch-basin to prevent spills or something as complex as redesigning an operation to increase efficiency and reduce waste. Simple things such as changing production technology to improve efficiency and reduce the amount of waste.

Often, choosing the right solution or technology, e.g. water-wash flexographic plates or less harmful solvents, can contribute to a reduction of environmental pollution and minimization of risk related to lack of compliance with environmental rules and regulations. Doing a socially responsible business involves full awareness of the environmental impact of the production activity and taking effective actions to reduce it. It is worth taking even the smallest step towards reducing the amount of waste.

Why reduce waste in a package printing facility?

Every printing facility generates harmful waste that must be safely and legally managed. Managing waste costs a lot of money!. And usually, the things we discard are materials we paid for when we got them. Reducing the amount of waste we dispose of makes it possible to lower the costs. And it is the cost reductions that motivate printers the most to reduce waste and environmental impact of their production.

Waste reduction contributes to:

• Improved work environment and worker safety.
• Reduced liability.
• Increased efficiency.
• Improved competitiveness – clients pay more and more attention to eco-standards of their suppliers.
• Fewer regulatory.
• Better environmental.
• Increased brand awareness and CSR opportunities.

What can be considered and done to reduce waste?

There are many ways to prevent pollution at flexographic printing facilities. We present several good practices whose implementation will lead to a reduced impact of production on the environment:

1. Keep work areas clean and well organized to help prevent accidents.
2. Use drip pans and splash guards where spills frequently occur.
3. Fix leaks immediately.
4. Do not buy more than is needed. Optimize inventory so that leftovers do not become waste and renewed cost.
5. Purchase the largest practical container. Ink, solvent and chemical containers always end up as waste.
6. Purchase the least toxic or hazardous product available. Check the material safety data sheets for the products you purchase. If the product is toxic or hazardous, ask your supplier for alternatives.
7. Use the oldest items first (gold rule: first-in, first-out).
8. If you do have excess or unneeded materials, see if your supplier can take them back or sell them.
9. Include the cost of disposal when making purchasing decisions. What looks like the cheapest option may cost more because of disposal or other management costs.
10. Store materials in a way that keeps them from being damaged.
11. Inspect storage areas regularly for leaks.
12. Make sure all items are clearly labelled. Store products in original containers.
13. Store wastes separately and is sure they are properly labelled to make it easier to dispose of, reuse or recycle them.
14. Store items that could leak in a place where leaks will be contained and easily spotted.
15. Make a list of your waste, then try to find a way to reduce or eliminate each of them. For example, change harmful solvents to water-based, mild and environmentally friendly detergents. Replace CtF technology with CtP technology. Computer-to-plate technology has eliminated negatives, silver and other chemicals from pre-press and significantly improved the efficiency of many flexographic printers. Waste and consumption of utilities have been greatly reduced.
16. Analyze industry standards as far as production technology goes, from pre-press to post-press. Regular costs of recycling, treatment and reprocessing can be easily calculated. Consider investing in new machines or equipment that will significantly reduce the impact of production on the environment, lower the need for harmful materials and reduce utility consumption.
17. Automate selected processes, e.g. post-press plate washing or anilox cleaning significantly reduces the consumption of water and cleaning agents extending the life of the plate. Remember that every photopolymer plate damaged during hand washing, which is common, becomes unnecessary waste.
18. Implement regular procedures for quality control (anilox, plate, and proof inspection). It leads to large reductions in reprints which generate additional waste and costs.
19. Build environmental awareness among employees by training them regularly concerning procedures and in-house quality control.

In nature there are neither rewards nor punishments – there are consequences.

Robert Green Ingersoll