1. Company insight > Printing
PACKAGING & CONVERTING INTELLIGENCE | www.pci-mag.com58
W
hereas environmental
regulations are placing
increasing demands on
consumer products, consumer
packaged goods manufacturers
(CPG) must continue to look for new
ideas to reduce the environmental
footprint of their packaging. Over the
last decade they have downgauged
their materials, tested natural sources
to replace chemical polymers and
recycled wherever possible.
But what else can be done,
particularly when most of the
packages on the shelf are printed?
Should printing be disregarded when
calculating the environmental footprint
of a packaging?
DuPont Packaging Graphics decided
to answer all these questions. In
Europe, the print form market for flexible packaging is
mainly split between two printing technologies:
flexography and rotogravure. DuPont has been an active
player and a leader in the flexographic industry. It was
important for DuPont to document and confirm the
sustainable benefits of flexographic processes compared
with other printing technologies.
Industry-wide solutions
The packaging industry is a large area of improvement
regarding energy efficiency and the reduction of carbon
footprint. Ten years ago DuPont Packaging Graphics
launched the DuPont™ Cyrel®
FAST thermal technology
for flexographic plate processing, completely eliminating
conventional chemical solvents and aqueous washout
solutions and reducing associated energy consumption.
In 2006 DuPont identified a group of tradeshops and
converters in Europe and in North America that it could
work with to measure the environmental footprint of the
whole packaging printing process. For DuPont it was
important to contribute to best packaging practices and to
make the findings publicly available.
In Europe, the Confederation of the Food and Drink
Industries (CIAA) strongly recommended the use of ISO
14040 guidelines, which were internationally recognised and
provided scientifically reliable conclusions. In January 2007,
DuPont adopted the ISO 14040 series methodology and
launched a lifecycle assessment (LCA) to document the
A green impression
Despite the packaging industry’s efforts to improve its environmental practices, there are
still many aspects of eco-packaging to be explored. DuPont Packaging Graphics’
Charlotte Debare describes how consumer packaged goods manufacturers can reduce
the environmental footprint of their packaging.
The conclusions from the aligned
plastic model indicate that flexo
printing results in an overall 51%
reduction of greenhouse gas
emissions and 48% savings in non-
renewable energy consumption.
Figure 1. Electricity energy sources vary from country to country.
Electricity production in Europe
DuPont’s Cyrel
FAST thermal
technology
eliminates
the need for
conventional
chemical solvents
and aqueous
washout solutions.

2. Company insight > Printing
PACKAGING & CONVERTING INTELLIGENCE | www.pci-mag.com 59
environmental impacts of flexographic
and rotogravure imaging and printing.
DuPont examined all the related
materials and key environmental
releases for greenhouse gas emissions
and non-renewable energy
consumption. It took into account
inputs and outputs associated with the
chemistries, substrates, inks, packaging
and other materials that were needed
during the phases of packaging
production until the end of the press.
The LCA considered and credited
environmental benefits for recycled or
reused materials. It also included the
heating credit for incinerated materials.
The LCA included external gap
analyses (provided by Five Winds, an
international lifecycle consulting firm) and it completed a
critical peer review.
When rotogravure is compared with flexographic
printing in the LCA, there are differences in the processes
that may lead to higher energy, ink and solvent use. In
addition, the LCA found some rotogravure printers that
have a higher scrap percentage than flexographic printers
due to the more complex printing procedure. Normally
rotogravure also requires increased electricity, especially
for drying, than a comparable flexographic printing press.
The conclusions from the aligned plastic model indicate
that flexo printing results in an overall 51% reduction of
greenhouse gas emissions and 48% savings in non-
renewable energy consumption.
In Europe, energy sources vary greatly from country to
country (Figure 1) and the impact on the overall
greenhouse gas emissions and energy consumption for the
printers has been highlighted by an additional sensitivity
study. In order to reduce the impact of varying electricity
grids, substrate types, fuel sources and waste practices
DuPont developed aligned models. A specific aligned
model was developed for plastic substrates in order to
illustrate the inherent technology
differences between flexographic and
rotogravure printing. A substrate film
mix was assumed based on 33.3% PET,
33.3% PE and 33.3% OPP.
The conclusions from the aligned
plastic model indicate that flexo printing
results in an overall 51% reduction of
greenhouse gas emissions and 48%
savings in non-renewable energy
consumption.
Flexography calculator
To actively support the growth of
flexography, DuPont developed a
computer calculator that provides
accurate figures illustrating the
benefits of using flexography (Figure 2).
For example, one million square metres of printed plastic
packaging substrate generates 390t of CO2 equivalent with
rotogravure and only 195t of CO2 equivalent in flexography.
The conversion to flexography also allows an energy
saving of 992MWh.
The DuPont calculator translates the 992MWh saving into
a scale of household consumptions. For example, to obtain
the same energy savings 30,520 lamps must be switched off
for one year or 8,700 TVs eliminated.
DuPont is making this calculator available to all CPGs who
want to quantify the environmental benefits of choosing
flexography. The DuPont calculator also compares Cyrel
FAST thermal technology (with PET developer material) with
solvent-based digital plate making. Thermal imaging process
results in 51% savings in greenhouse gas emissions and 60%
savings in non-renewable energy when compared with the
solvent flexo technology for a 0.067 plate (1.7mm thick).
Today, DuPont Cyrel FAST plate-making technology has
been transposed into sleeve printing forms. Cyrel FAST round
image carriers provide best-in-class precision and consistency
especially to repeat jobs. Modern flexography has still more
than one string to its bow to surprise and convince the most
reluctant marketeers about infinite printing options. ■
Further information
DuPont de Nemours
www.cyrel.eu/sustainability
Figure 2. DuPont’s computer calculator provides accurate figures
showing the benefits of flexography.
Rotogravure vs flexography calculator Sept 2008
Charlotte Debare, DuPont Packaging Graphics’
project manager for sustainability.
Thermal imaging process results
in 51% savings in greenhouse gas
emissions and 60% in non-
renewable energy.