07.03.2016
In the first article in this series, we explained what migration means, how label printing is affected by it, and what migration risks exist. Now we will look at how label printers can address migration issues and what criteria must be considered for low-migration label printing. This article focuses on the organizational implementation of low-migration label printing.
As described in the first article, the migration value of a label, or the migration behavior of packaging, is difficult to determine immediately during production. Simple quality control of the label, such as that used for print registration or color, cannot be applied. Instead, a process-based approach is required: the label must be produced in such a way that it is virtually impossible for harmful quantities of substances to migrate from the label into the food. Such risk minimization can only take place if the entire manufacturing process of a label is examined from order receipt to order dispatch and potential migration risks are eliminated. There is no magic formula for switching to low-migration printing and implementing it in practice. However, it is generally worthwhile to follow the value-added process when analyzing risk minimization:
1. Order intake
The market segments and applications handled by a label printing company can be used to determine the need for action and the relevance of migration issues. Only once this analysis has been carried out can appropriate implementation strategies be defined. Regardless of the implementation strategy, however, it makes sense today to be able to assess at the quotation stage whether the order in question poses a migration risk and whether this risk is sufficiently specified. Standardized checklists have proven useful in this regard.
2. Prepress
Once the migration risk has been determined, a suitable production method must be specified. Put simply, there are two options: on the one hand, the migration risk can be minimized through the technical design; on the other hand, colors and auxiliary materials can be used which, when applied correctly, allow correspondingly low migration values. Transfer migration can be counteracted, for example, by using an appropriate protective coating or laminate film. If it is not possible to incorporate functional barriers, the migration risk must be reduced by choosing the right ink system. However, without a precise description of the end product, it is virtually impossible to determine an effective production method.
3. Procurement
The procurement of the substrates, inks, and auxiliary materials required for production should also be analyzed in detail. As a rule, substances specified for low-migration printing also have specific processing and handling requirements. It must therefore be checked in advance whether the necessary processing and handling of these substances is possible in the print shop.
In addition, new production resources should also be evaluated from the perspective of low-migration printing requirements wherever possible. For example, it is advantageous to use machines that are open and easily accessible.
4. Production planning and quality assurance
Only in very few cases will a label printing company consider completely switching its production to low-migration printing. Production planning must therefore ensure that "standard" and low-migration jobs are processed separately from each other. A common misconception is that low-migration inks and standard inks can be processed on the same machine depending on the job. However, mixing the two inevitably leads to contamination (via anilox rollers, deflection rollers, etc.) and negates any efforts to achieve low-migration printing. It is therefore essential to ensure that dedicated production equipment is provided. This can pose a considerable organizational and planning challenge, especially in smaller label printing companies.
Low-migration printing does not significantly change the basic tasks of quality assurance. However, the introduction of GMP (Good Manufacturing Practice) and the resulting process and logistics adjustments should not be underestimated. In particular, the issue of consistent and complete traceability should be subjected to a detailed analysis. It may be worthwhile to consider consulting a specialist agency.
5. Printing and finishing, cleaning, maintenance, and servicing
This is where decisions are made about which materials come into contact with each other, when, and how. Implementing a low-migration job in accordance with the specifications of prepress and production planning is often the smaller task. The significantly greater challenge lies in converting and structuring auxiliary processes such as cleaning, maintenance, and servicing, which in most print shops take on the character of central services and are difficult to separate. For example, anilox rollers are usually used across multiple machines and cleaned centrally in a bath. The material composition of lubricants, cleaning agents, printing plates, etc., and the resulting migration risk are also largely unknown. In addition to the actual printing of the labels, it is therefore primarily the auxiliary processes that must be subjected to a thorough analysis.
6. Order picking, warehousing, and shipping
With the introduction of GMP, hygienic and logistical requirements are also being imposed on printing companies. This has resulted in separations in warehousing and increased hygiene requirements for staff (hairnets, smoke-free production, hand hygiene, etc.). The hygiene requirements for the delivery and collection of materials and print jobs often cause headaches. Dock locks for commercial vehicles or similar structural measures should therefore be included at an early stage in an implementation concept for the low-migration production of labels.
Comprehensive approach
A sustainable and coherent production concept for the manufacture of low-migration labels can only be established with a comprehensive approach. All factors relevant to production – people, resources, and methods – must be taken into account. As described in the introduction, no factual proof of migration-free production can be provided during label production. The only option is to identify and eliminate potential migration risks and establish processes that guarantee this risk minimization in the long term. However, if pursued consistently, the switch to low-migration printing also offers label printers an opportunity to differentiate themselves from their competitors and position themselves on the market as a competent supplier of food labels.
Easily accessible flexographic printing units on the Gallus ECS 340, sleeve systems and chamber doctor blades for quick and easy job changes
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Possible implementation strategy based on print volume and migration risk
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07.03.2016
In the first article in this series, we explained what migration means, how label printing is affected by it, and what migration risks exist. Now we will look at how label printers can address migration issues and what criteria must be considered for low-migration label printing. This article focuses on the organizational implementation of low-migration label printing.
As described in the first article, the migration value of a label, or the migration behavior of packaging, is difficult to determine immediately during production. Simple quality control of the label, such as that used for print registration or color, cannot be applied. Instead, a process-based approach is required: the label must be produced in such a way that it is virtually impossible for harmful quantities of substances to migrate from the label into the food. Such risk minimization can only take place if the entire manufacturing process of a label is examined from order receipt to order dispatch and potential migration risks are eliminated. There is no magic formula for switching to low-migration printing and implementing it in practice. However, it is generally worthwhile to follow the value-added process when analyzing risk minimization:
1. Order intake
The market segments and applications handled by a label printing company can be used to determine the need for action and the relevance of migration issues. Only once this analysis has been carried out can appropriate implementation strategies be defined. Regardless of the implementation strategy, however, it makes sense today to be able to assess at the quotation stage whether the order in question poses a migration risk and whether this risk is sufficiently specified. Standardized checklists have proven useful in this regard.
2. Prepress
Once the migration risk has been determined, a suitable production method must be specified. Put simply, there are two options: on the one hand, the migration risk can be minimized through the technical design; on the other hand, colors and auxiliary materials can be used which, when applied correctly, allow correspondingly low migration values. Transfer migration can be counteracted, for example, by using an appropriate protective coating or laminate film. If it is not possible to incorporate functional barriers, the migration risk must be reduced by choosing the right ink system. However, without a precise description of the end product, it is virtually impossible to determine an effective production method.
3. Procurement
The procurement of the substrates, inks, and auxiliary materials required for production should also be analyzed in detail. As a rule, substances specified for low-migration printing also have specific processing and handling requirements. It must therefore be checked in advance whether the necessary processing and handling of these substances is possible in the print shop.
In addition, new production resources should also be evaluated from the perspective of low-migration printing requirements wherever possible. For example, it is advantageous to use machines that are open and easily accessible.
4. Production planning and quality assurance
Only in very few cases will a label printing company consider completely switching its production to low-migration printing. Production planning must therefore ensure that "standard" and low-migration jobs are processed separately from each other. A common misconception is that low-migration inks and standard inks can be processed on the same machine depending on the job. However, mixing the two inevitably leads to contamination (via anilox rollers, deflection rollers, etc.) and negates any efforts to achieve low-migration printing. It is therefore essential to ensure that dedicated production equipment is provided. This can pose a considerable organizational and planning challenge, especially in smaller label printing companies.
Low-migration printing does not significantly change the basic tasks of quality assurance. However, the introduction of GMP (Good Manufacturing Practice) and the resulting process and logistics adjustments should not be underestimated. In particular, the issue of consistent and complete traceability should be subjected to a detailed analysis. It may be worthwhile to consider consulting a specialist agency.
5. Printing and finishing, cleaning, maintenance, and servicing
This is where decisions are made about which materials come into contact with each other, when, and how. Implementing a low-migration job in accordance with the specifications of prepress and production planning is often the smaller task. The significantly greater challenge lies in converting and structuring auxiliary processes such as cleaning, maintenance, and servicing, which in most print shops take on the character of central services and are difficult to separate. For example, anilox rollers are usually used across multiple machines and cleaned centrally in a bath. The material composition of lubricants, cleaning agents, printing plates, etc., and the resulting migration risk are also largely unknown. In addition to the actual printing of the labels, it is therefore primarily the auxiliary processes that must be subjected to a thorough analysis.
6. Order picking, warehousing, and shipping
With the introduction of GMP, hygienic and logistical requirements are also being imposed on printing companies. This has resulted in separations in warehousing and increased hygiene requirements for staff (hairnets, smoke-free production, hand hygiene, etc.). The hygiene requirements for the delivery and collection of materials and print jobs often cause headaches. Dock locks for commercial vehicles or similar structural measures should therefore be included at an early stage in an implementation concept for the low-migration production of labels.
Comprehensive approach
A sustainable and coherent production concept for the manufacture of low-migration labels can only be established with a comprehensive approach. All factors relevant to production – people, resources, and methods – must be taken into account. As described in the introduction, no factual proof of migration-free production can be provided during label production. The only option is to identify and eliminate potential migration risks and establish processes that guarantee this risk minimization in the long term. However, if pursued consistently, the switch to low-migration printing also offers label printers an opportunity to differentiate themselves from their competitors and position themselves on the market as a competent supplier of food labels.
Easily accessible flexographic printing units on the Gallus ECS 340, sleeve systems and chamber doctor blades for quick and easy job changes
Possible implementation strategy based on print volume and migration risk