The report describes the technical and economic evaluation of the substitution of nonhazardous materials for the manufacture of flexible packaging in a wide web flexographic printing process. The objective of the study was to evaluate, on a technical and economic basis, the impact of the substitution of water-based inks for solvent-based inks in a flexographic printing process. The ink substitution resulted in a reduction in the emissions generated from the printing process. For each percent increase in water-based ink utilization, a reduction in VOC emissions of 14 pounds was calculated. This was based on a usage rate of about 2250 pounds of ink per week which caused a VOC emission of about 1570 pounds. The substitution, typically, did not adversely affect product quality or nonhazardous scrap waste generation. An average reduction of 95% of liquid F003 waste from waste ink and cleaning solvents was recorded during the study period, but was ascertained to be due to operational practice changes. Additional benefits resulting from the reduction of VOC emissions and liquid hazardous waste have been an improved working environment from reduced indoor air pollutants, reduced handling of hazardous solvents by employees, and the appreciation by company employees of the need to make a conscious effort to further reduce waste generation.

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