With the rapid development of new technologies and growing environmental awareness, benzene-based gravure inks have gradually been phased out. In their place, ester-soluble and alcohol-soluble inks—especially water-based inks—have gained popularity due to their eco-friendly properties. These inks have sparked a significant shift in the industry’s approach to sustainability. According to reports, in developed regions such as Europe and the United States, water-based inks now account for over 80% of the gravure ink market. However, in China, solvent-based inks still dominate the market, with many companies remaining cautious about adopting water-based alternatives. This article aims to provide an overview of the benefits and challenges of water-based inks, hoping to contribute to a broader understanding and more widespread use of this environmentally friendly technology.
Main Advantages of Water-Based Inks
(1) The primary solvent in water-based inks is water, with small amounts of alcohols like ethanol or isopropanol added to improve resin solubility, pigment dispersion, and drying performance. These inks emit significantly fewer volatile organic compounds (VOCs), reducing air pollution and improving the working conditions for printers. They are also safer for employees’ health, making them a preferred choice in environments where safety is a concern.
(2) Although the initial cost of water-based inks may be slightly higher than that of solvent-based inks, the main component—water—is inexpensive. As a result, the overall cost of using water-based inks is comparable or even lower than that of traditional inks, making them a cost-effective option in the long run.
(3) Domestic production of water-based inks has matured, especially for non-metallic applications. While earlier versions had issues with slow drying, low gloss, and poor water resistance, modern formulations have made great improvements. Today, water-based inks are well-suited for high-quality packaging in sensitive industries such as food, pharmaceuticals, tobacco, and beverages, where hygiene and safety are critical.
(4) Water-based inks eliminate the fire risks associated with flammable solvents and reduce the dangers of static electricity, making them a safer alternative for industrial printing operations.
Main Challenges of Water-Based Inks
(1) A key challenge lies in the resin amination process, which requires expensive organic amines. To cut costs, some manufacturers substitute these with ammonia, which can cause strong odors and pose health risks. The Chinese Environmental Protection Agency set limits on ammonia content in water-based inks starting in 2007, capping it at 3%. Since ammonia is considered harmful, not all water-based inks meet the strict requirements for food and pharmaceutical packaging, where no irritating smells are acceptable.
(2) Another issue is the slower drying speed of water-based inks, especially on non-absorbent substrates like transfer paper. This can lead to longer drying times, requiring higher temperatures or reduced printing speeds, which may affect efficiency. For large solid areas, the drying process can be several times slower than with solvent-based inks, posing challenges for high-speed production lines.
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