Tips for green paper-package converting

Open virtually any newspaper or business magazine today, and you're bound to see a report or an advertisement about sustainability. Innovative companies are increasingly using manufacturing processes that are less harmful to the environment and are making products that are far more eco-friendly than ever before.

In the highly competitive consumer packaged goods marketplace, environmentally sustainable products are especially important. As consumers become ever more savvy, they are looking for products with all-natural ingredients and are paying more attention to various brands' environmental stances. Therefore, CPG brand managers must turn the same attention to their packaging and manufacturing as they do to their product ingredients.

But being environmentally responsible also presents a new set of challenges. For brand managers, graphic designers, packagers and converters, the rising cost of operations and consumables means that all parties in the supply chain must be mindful to ensure that their printed packaging is created in the most cost-effective ways possible, yet is still appealing to customers. Add environmental friendliness to the mix, and you may get an earful about cost-to-benefit ratios, print quality issues and so on.

But the truth of the matter is that eco-friendly design, printing and packaging can, in fact, be cost-effective, good for Mother Nature and compelling to shoppers. All that is required is attention to some key elements during the project-planning phase.

Among the options to consider when selecting eco-friendly paper-based packaging are virgin-fiber, recycled and tree-free materials.

The strongest and most pure paper fiber that comes directly from trees is called virgin fiber. Because it has not undergone prior printing or converting, papers made with virgin fiber can be the cleanest papers available, depending on the bleaching process used. However, virgin paper has the most direct effect on the consumption of natural resources. Fortunately, virgin fiber can be traced to its origins via third-party certification programs, such as the Forest Stewardship Council® (FSC [www.fscus.org]), the Sustainable Forestry Initiative, Inc.® (SFI [www.sfiprogram.org]) or the Programme for the Endorsement of Forest Certification™ (PEFC [www.pefc.org]). This “chain of custody” certification assures users that that no old-growth forests are being used as sources of fiber.

Recycling has become an increasingly important factor in paper manufacturing. It is estimated that recovered fiber now accounts for approximately 37 percent of the domestic raw materials used to make paper products. Recycling paper, in fact, takes quite a bit of pressure off landfills and forests alike. According to the Environmental Defense Fund (EDF [www.environmentaldefense.org]) and its Alliance for Environmental Innovation, compared to the manufacture of coated virgin fiber paper, recycled paper reduces total energy consumption by 38 percent; net greenhouse gas emissions by 40 percent; particulate emissions by 36 percent; wastewater by 32 percent; and solid waste by 46 percent.

Over the last decade, recycled paper—which can include post-industrial waste, post-consumer waste (PCW), totally recycled fiber or blends of each—has greatly improved in quality. In many cases, recycled paper performs as well as virgin stock and at competitive prices.

In addition to being eco-friendly, fiber from other plants—such as kenaf, hemp, flax, cotton or combinations thereof—can be used as an alternative to virgin wood pulp. Plant-fiber papers, especially kenaf and hemp, tend to be more durable than virgin wood fiber papers. Kenaf, in particular, contains less lignin (an amorphous polymer that provides rigidity) than trees, requires fewer chemicals and less energy to process, and is naturally acid-free and recyclable.

It is important to remember that coated stock is more difficult to recycle than uncoated. This is due to the clay coating that gives the paper its smooth, shiny surface characteristics. In fact, during the recycling process, up to 40-percent less fiber can be extracted from coated paper versus uncoated.

Brand managers and package designers should consider using more uncoated paper. Premium uncoated PCW papers can provide great results in multicolor offset printing. Uncoated paperboard feels natural to the touch, and its tactile appeal is especially suitable for fragrances and high-end personal-care products where consumers tend to keep the secondary packaging.

If a package design must have a smooth surface like that of coated stock, one alternative to consider is supercalendered paper. Supercalendering is a process in which uncoated paper is run through a series of chrome and fiber rollers under heat and high pressure to produce a smooth, glossy surface appearance closer to that of coated paper.

Some tips for cost-effective, sustainable print production include the following:

Size paper to minimize waste. For print runs of 5,000 or more, consider ordering a custom-size sheet of paper that meets exact design specifications, versus a standard-size sheet that would require significant trimming. Doing so minimizes paper, chemical and energy waste, which can translate into dollar savings.

Use fewer folds for less waste. Complex folding specifications for a printed piece or package design may be appealing, but they require the use of more paper or paperboard, which can quickly increase costs. For example, adjusting the size of a pocket or a folded section might reduce complexity.

Gang multiple print jobs that use the same paper stock and ink to reduce paper usage and lower the number of make-readies and plates.

Use digital photography where appropriate to reduce or eliminate paper usage.

Use digital proofing and electronic file delivery to minimize paper waste and to speed the production process.

When it comes to selecting ink, two eco-centric factors are involved: the effect on the printing process and the recyclability of the finished, printed piece. Areas of concern here include volatile organic compounds (VOCs), nonrenewable resources and the heavy metals used in pigments.

More and more printers are reducing their use of VOCs and are offering their customers inks made with vegetable oils as environmentally preferred alternatives to petroleum-based inks, which contain ozone-depleting distillates and VOCs (heat-set web offset and gravure inks emit the most). VOCs are released into the atmosphere during the print-drying process. But, while many of these pollutants can be eliminated using catalytic converters, petroleum is not a renewable material.

Vegetable oil-based inks, or “agri-based” inks, offer an attractive alternative to petroleum-based products. These biodegradable, low-VOC inks are well suited for use on uncoated paper and are made with renewable resources such as soy, linseed, cottonseed, tung or china wood oil. The percentage of soy or vegetable oil may vary from 20 percent to 100 percent of the ink's vehicle, which is the part of the ink that carries the pigment. Remember that although agri-based inks may contain petroleum, they do not have the VOC levels of solvent-based ink formulations, which can be as high as 40 percent.

To save money and environmental resources, designers may consider using fewer inks or using spot colors for innovative designs with punch. Note though that the use of metallic and fluorescent inks should be carefully considered, as they may have some toxicity. In addition, the use of fewer full-page ink floods also reduces the amount of processing that is required when recycling recovered paper. Finally, downsizing paper-sheet size when using ink bleeds can significantly reduce trim waste while lowering the expense of upgrading to the oversized sheet sizes typically used for bleeds.

Many finishing techniques exist that can add unique and dramatic elements to a printed package. Embossing and die-cutting are two environmentally friendly processes that can add depth and dimension to a package without the use of chemicals or inks. Embossing can be one-level, multi-level, registered with inks or sculpted, which is especially beautiful on secondary packaging, adding texture and shelf appeal.

Die-cut windows in secondary packaging can add a level of interactivity and can maximize the impact of primary packaging. Also, both embossing and die-cutting dies can be reused, thereby maximizing investments.Engraving is another elegant, classic printing technique that has minimal impact on the environment, as most engraving inks are either water- or vegetable-based.

Putting even a few of these paper-package printing tips into practice not only will help your business protect the environment, but will also keep your employees thinking innovatively when designing packaging.