Environment-friendly and cost-effective solution for flexible packaging printing process by advancement in engraving process.

Organic solvents have been commonly used in the printing process for a long time in gravure printing applications. Using organic solvents in solvent-based ink is responsible for fire hazards, volatile organic compounds emission, and increasing extra printing costs. The current study aimed to replace solvent-based ink with water-based ink to reduce volatile organic compound emissions and carbon footprints in gravure printing without affecting overall printing quality in order to fill a research gap because none of the studies were reported as best of all authors' knowledge. The polyethylene terephthalate film was printed by laser engraved cylinder having reduced engraving cell depth compared to electronically engraved printing cylinders which result in less consumption of printing ink, hence reducing the raw materials consumption. The cost of printing one kg of polyethylene terephthalate film with water-based ink was reduced by 1.85US$, and volatile organic compounds emissions were reduced from 3373 ppm to 2478 ppm compared to solvent-based ink. The use of water-based ink also reduced the carbon footprint by 3.04 kg. The current study shows that strict implementation of water-based ink has a high potential for saving the cost and reducing the emission of volatile organic compounds, which are very dangerous to the ambient environment, humans, and society. This study's outcome will help prepare the benchmark for green manufacturing systems in gravure printing applications to improve the environment and humanity. [ABSTRACT FROM AUTHOR]