Nitrocellulose-Free Polyurethane Ink System For Flexible Packaging

The transition toward a circular packaging infrastructure requires adapting the chemical binders used in flexible packaging printing. To address regulatory and material recovery requirements, hubergroup deployed an alternative to conventional nitrocellulose binders through a specialized polyurethane-based liquid ink system designed for frontal, reverse, and lamination printing applications.

Addressing the Industrial Challenge
Historically, nitrocellulose and polyvinyl chloride served as standard binders in solvent-based printing due to their established mechanical properties. Stricter recyclability demands within the packaging sector necessitated alternative chemical structures. hubergroup utilized its internal chemical formulation division to develop raw polyurethane materials specifically adapted for industrial printing systems, integrating these components into high-performance ink formulations. This vertical integration allows the manufacturer to align raw material properties directly with the technical specifications required by flexible packaging converters, bypassing the need for external binder development.

Technical Architecture and Responsibilities
The Gecko CyclOne platform operates on a modular system architecture. Pigment concentrates function as the base layer and are modified for specific printing methods—including frontal, reverse, and lamination processes—through the application of specialized additives. The technical scope of the system covers white inks, CMYK process colors, varnishes, and primers. It is compatible with both mono-solvent applications and standard solvent mixtures. Carsten Zölzer, CCO Print Solutions at hubergroup, stated: "Our in-house polyurethane expertise enables us to develop raw materials specifically for our ink systems, thereby delivering the performance that converters expect from high-quality solvent-based printing."

Deployment and Operational Integration
The polyurethane system is engineered for implementation in existing flexographic and gravure printing environments. Because the application parameters of polyurethane-based inks closely align with established nitrocellulose-based processes, facilities can integrate the new material formulations with minimal mechanical modification to existing production lines. Dr. Lutz Frischmann, Product Director for Flexible Packaging at hubergroup, noted: "Although the switch requires some adjustments, it does not entail any fundamental changes to existing processes." The modular formulation approach reduces the variety of base inks required in inventory, directly impacting the operational efficiency and stock management processes for printing facilities.

Applications and Process Impact
The deployment of this technical solution specifically targets flexible packaging operations aiming to stabilize process efficiency while altering their chemical footprint. Prior iterations of polyurethane-based solutions were initiated by the company in 2015, and the current product line supplements the existing technical portfolio, which includes the Gecko Platinum and Gecko Xtreme White series. By transitioning to a modular, nitrocellulose-free infrastructure, operators can maintain necessary mechanical and optical specifications while aligning with technical requirements for circular material recovery.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.hubergroup.com