VIGC presentation during Labelexpo 2015 in Brussels on ink migration, set-off, maximum ink coverage, process evaluation and control.

1. Design4Food
Optimized inking for food packaging
Fons Put
30 September 2015
Fons.Put@vigc.be
www.vigc.be

2. Typical packaging printing proces
§ Process colors
— Illustrations
§ Spot colors
— Branding
§ Laquer/varnish
— Finishing & protection
9/29/15 Optimized inking for food packaging 2

3. Critical side effects (1)
§ Set-off (scope)
— Contact between printed side and reverse side in a
printed pile or roll
— This contact can cause a transfer of ink & laquer to
the reverse (unprinted) side of the substrate
9/29/15 Optimized inking for food packaging 3

4. Critical side effects (2)
§ Migration (out-of-scope)
— Transfer of chemicals to the food-contact side
— Example: Rüdiger Helling (Lua Dresden)
9/29/15 Optimized inking for food packaging 4
Figure 2: Colored printed la
GC-MS mass trac
.
R
Within the survey, 65 su
identified in the printing lay
detected and quantified in
evaluation.
In general, UV-cured inks
products as well as low molec
Plasticizers were found to
flexographic printing (e.g. pac
In the case of cold- and
cardboard solvents are the mo
Some cardboard boxes p
encountered, with high migra
Low-migration printing ink
always used in critical cases.
Intensively printed, self-sti
contamination pathway. Mi
food easily reached the mg/kg
Transparency within the sup
compliant and safe food pack
Consideration of NIAS (“N
contamination source caused
products are a future task
Based on the results of the p
introduce specific requiremen
first and second draft were alr
For further details and resul
(http://www.ble.de).
Verification of ink
composition
Analysis at different
storage times
Analysis at the
end of shelf life
Food / Foodsimulant
Specific compound analysis
by GC-TOF/MS GC-MS LC-MS-MS LC-GC
Applied techniques:
- microtome cutting / IR
- chemical testing
- GC-TOF/MS
- GC/MS
- LC/MS/MS; LC-DAD/FD
Package
Parameters:
- Layer design
- Printing technique
- Kind of ink
- Ink characterization
- Specific printing ink components
If calculated 100 % migration
is >10 µg/kg food
sausage packed in multi-layer plastic casing
Microtome cutting of the complex layer
Applied technique: UV flexo printing
outer face
printing ink
polyamide
bonding polymer (PUR)
polyethylene red coloured
bonding polymer (PUR)
polyamide
food contact side
Practical Examples
Irgacure 127
2-Benzyl-2-(dimethylamino)-
4-morpholino-butyrophenone
Irgacure 127
2-Benzyl-2-(dimethylamino)
155 ppb
Irgacure 127
10 ppb 2-Benzyl-2-(dimethyl-
amino)-4-morpholino-butyrophenone
I. II.
M

5. Regulations concerning set-off
§ Best practices: Regulation EC 2023/2006
— ‘Good manufacturing practice for materials and articles
intended to come in contact with food’
— There shall be no migration from printed side to food-
contact side!
— Applies to the total packaging chain:
— Substrate suppliers
— Ink manufacturers
— Adhesive manufactures
— printers/convertors
— Packers/fillers
— Dixtributors
— Retailers
9/29/15 Optimized inking for food packaging 5

6. Set-off solutions in the market
§ Dry contact surfaces
— Balanced ink drying
9/29/15 Optimized inking for food packaging 6

7. Set-off solutions in the market
§ Prolong the time before contact
— Press design
9/30/15 Optimized inking for food packaging 7

8. Set-off solutions in the market
§ Accelerate drying through hot air, infrared
light, …
9/30/15 Optimized inking for food packaging 8

9. Set-off solutions in the market
§ Reduction of the contact surface
— use of powder
9/30/15 Optimized inking for food packaging 9

10. Set-off solutions in the market
§ Artificial ink drying
— UV-inks, Low Energy UV
9/30/15 Optimized inking for food packaging 10

11. What can be done before printing?
§ Design: critical zones for set-off
— Heavy ink coverage
9/30/15 Optimized inking for food packaging 11

12. Design for Food
§ Concept
— Lowering ink consumption without affecting color
— Applicable in the design stage or at the plate making
proces
— ICC-profiles to calculate (design) or recalculate
(plate making) separations
§ Advantages
— Lower risk for set-off
— Less material (ink) means less migration (linear
relationship)
9/30/15 Optimized inking for food packaging 12

13. ICC-profiles for ink reduction
§ Maximum ink limit
— A threshold for the total ink coverage
— ISOcoated_v2_eci: 325% max. Inkt limit
— Coated_Fogra39L_VIGC_220: 220% limit
9/30/15 Optimized inking for food packaging 13

14. ICC-profiles for ink reduction
§ Use of black in color separation
— Colors can be composed with different amounts of
black and color inks.
— Separation with medium black
— Separation with heavy black
9/30/15 Optimized inking for food packaging 14

15. Print trials
§ Evaluation of the printed color gamut
— Start: ISO 12647-2
— Substrate correction
— Laquer/Varnish effects
9/30/15 Optimized inking for food packaging 15

16. Print trials
§ Evaluation of the printed color gamut
— Example: low migration inks on cardboard
9/30/15 Optimized inking for food packaging 16
C M Y K A B C A B C
zwart (enkel)
2.4 3.6 6.0 A 1.1 2.4 3.6 6.0
0.7 2.4 3.6 6.0
A
2.4 3.6 6.0 A 0.9 2.4 3.6 6.0 A
A
0 0 0 20 0.3 2.4 3.6 6.0 A 0.5 2.4 3.6 6.0 A
1.4 1.5 2.4 4.0 A
CMY halftonen
RGB halftonen
0 0 0 10 0.3
0 0 0 40 1.1
0 0 0 60 1.8
70 70 0 0 1.2 1.5 2.4 4.0 A
4.0 C 1.1 1.5 2.4 4.0 A
3.5 1.5 2.4 4.0 C 0.8 1.5 2.4 4.0 A
4.0
4.0 A
4.0 A
0 0 40 0 0.7 1.5
40 0 0 0 2.9 1.5 2.4 4.0
0 40 0 0 1.3 1.5 2.4
0 0.8
C 0.4 1.5 2.4 4.0 A
A 0.5 1.5 2.4 4.0 A
1.5 2.4 4.0 C 1.0 1.5 2.4
40 0 40 0 2.7 1.5 2.4 4.0 C 0.6
70 0 70 0 3.0 1.5 2.4
0.8 1.5 2.4 4.0 A
0 0
0 0
70
40 40 0 0 0.8 1.5 2.4 4.0 A
1.5 2.4 4.0 A
A
1.5 2.4 4.0 B 0.4
1.5 2.4 4.0 A 0.4 1.5 2.4 4.0 A
0 80 2.6 2.4
2.4 4.0 A 0.4 1.5
0 70
3.6 6.0 B 0.9 2.4 3.6 6.0
2.4 4.0 A
0 40 40 0 1.9 1.5 2.4 4.0 B 0.6 1.5 2.4
0 0 0 2.5
0 70 0 0 1.9
70
70 0
1.5 2.4 4.0 A
2.4 3.6 6.0 A
1.6 1.5 2.4 4.0
score
A
C
A
C
B
A
score
A
A
A
A
A
B
2.4 3.6
Secundaire kleuren
(samendruk 2 inkten)
variatie toleranties
ΔE2000
0.8 1.5 2.4 4.0
0.6 1.5 2.4 4.0
0.3 1.5 2.4 4.0
0.9 1.5 2.4 4.0
100 100 0 0 1.2 1.5 2.4 4.0
0 0 0 100
2.4 4.0
0.8 1.5 2.4
100 0 100 0 1.9 1.5 2.4 4.0
1.8zwart (volvlak)
0 100 100 0 2.5 1.5
1.5 2.4100 0 0
6.0 A
4.0
2.4 3.6 6.0 A0.4
Primaire kleuren
(inktkleuren)
digital deviatie toleranties
ΔE2000
4.0
1.0 1.5 2.4
4.00 0 100 0
100 0 0 0 1.0 1.5 2.4 4.0
0 2.8

17. Print trials
§ Evaluation of maximum ink limit
— 325% - 260% - 220%
9/30/15 Optimized inking for food packaging 17

18. Print trials
§ Evaluation of maximum ink limit
— Does a higher ink coverage produce a darker black?
9/30/15 Optimized inking for food packaging 18
325%
260%
220%

19. Print trials
§ Evaluation of maximum ink limit
— Does a higher ink coverage produces more set-off?
9/30/15 Optimized inking for food packaging 19
!

20. Print trials
§ Evaluation of maximum ink limit
9/30/15 Optimized inking for food packaging 20
400%
ECI%
320%
300%
260%
220%

21. Print trials
§ Evaluation of black in separation
— Identical colors
— without black ink, medium and maximum black
9/30/15 Optimized inking for food packaging 21

22. Print trials
§ Evaluation of black in separation
— Which separation type produces accurate colors?
— Example with low migration inks
9/30/15 Optimized inking for food packaging 22
No
black
ink
(
CMY
only)
Maximum
use
of
black
ink
Medium
use
of
black
ink

23. Print trials
§ Evaluation of black in separation
— Does the heavy use of black ink promotes stability in
printing?
9/30/15 Optimized inking for food packaging 23

24. Print trials
§ Evaluation of real-life design
9/30/15 Optimized inking for food packaging 24

25. Print trials
§ Evaluation of real-life design
9/30/15 Optimized inking for food packaging 25

26. Print trials
§ Evaluation of real-life design
— Mathematical method
— Sampling of dominant design colors
— Calculating 2 separations
— Original 325%, medium black
— 220%, heavy black
— Color measurement & difference (dE2000)
9/30/15 Optimized inking for food packaging 26

27. Print trials
§ Evaluation of real-life design
— Mathematical method
9/30/15 Optimized inking for food packaging 27
C M Y K L* a* b* ΔCIE2000 ΔL ΔC ΔH C M Y K ΔCIE2000 ΔL ΔC ΔH ΔCIE2000
1 10 70 52 2 56.0 41.8 19.8 3 2.5 -1.0 -1.5 1 68 48 10 3 3.0 -0.5 0.8 1
2 44 62 67 64 27.5 8.1 9.3 3 2.5 0.0 -2.2 23 51 57 74 3 3.0 0.7 1.6 1
3 35 85 64 57 26.1 23.1 8.6 2 2.6 -1.7 -0.8 13 78 51 68 2 2.8 -2.0 0.4 0
4 63 68 56 76 18.8 3.8 -0.1 3 3.5 -0.7 -1.2 37 48 35 88 3 3.2 -0.2 -1.4 1
5 59 77 64 86 14.6 5.2 2.0 3 3.5 0.2 -1.2 29 55 40 94 2 3.4 0.4 0.8 0
6 60 62 57 67 23.5 3.3 1.1 2 2.5 -0.4 -1.1 35 44 38 82 3 3.1 0.0 0.8 1
7 82 72 62 91 11.8 -0.6 -1.0 3 3.6 -0.8 -1.4 47 38 33 100 4 3.5 0.6 -3.0 2
8 69 80 61 89 12.6 3.5 0.0 3 4.0 0.0 -1.1 37 51 33 97 3 3.9 0.4 -1.9 1
9 35 80 63 45 31.3 24.9 10.1 4 3.9 -1.9 -1.9 12 74 51 60 3 3.6 -2.0 0.2 1
10 46 70 63 70 22.9 9.6 5.4 3 3.6 -0.3 -2.2 24 59 49 80 3 3.7 -0.3 1.0 1
11 53 60 60 63 27.1 4.8 4.2 1 1.2 0.4 -0.5 31 46 45 76 2 1.9 0.6 0.2 1
12 50 56 51 55 31.8 5.8 2.4 1 1.3 0.0 -0.5 31 45 38 68 1 1.1 0.0 0.1 1
separatie 1/2originele separatie: druk versus target separatie VIGC 220: druk versus targetKleurnr

28. Print trials
§ Evaluation of real-life design
— Visual method
— Comparison in a light cabinet
— 5 basis and 5 optimized samples
9/30/15 Optimized inking for food packaging 28

29. Conclusions
§ Food packaging printing is a specialised printing
proces
— Choise of substrate (odour, recycling)
— Choise of ink (low migration)
— Food-safe printing (set-off)
— Complexity of ink-drying
§ Protection against set-off by using an optimized
color separation (ICC)
— Choise of maximum ink limit: 220% is possible without
affecting colors
— Choise of black generation in separation: maximum
black further lowers the ink consumption and increases
color accuracy and stability
9/30/15 Optimized inking for food packaging 29

30. Click
to
edit
Master
Ctle
style
Campus Blairon 5, B-2300 Turnhout
+32 (0)14 40 39 90, info@vigc.be, www.vigc.be