For decades, solvent-based systems have been the industry norm, yet their environmental and health drawbacks are increasingly hard to ignore. Hazardous chemicals, flammable substances and toxic waste disposal requirements burden the process, exposing workers to risks and companies to mounting compliance costs.
Product manager of packaging at Fujifilm Graphic Communication, Zaheer Shaik, explains how eco-conscious advancements position businesses for success in a world where efficiency and responsibility go hand-in-hand. ‘Water washout technology eliminates the need for these harsh solvents, removing dangerous fumes, fire hazards and skin or respiratory risks. Moving to water-based systems facilities not only streamlines operations but fosters a significantly safer working environment,’ he maintains.
The environmental benefits of water washout systems speak volumes. Unlike solvent waste, which requires complex and costly disposal processes, the waste water generated in water-based systems can often be treated on-site and repurposed as grey water, further lowering environmental impact. According to Zaheer, this alternative approach reduces contamination risks and sidesteps the toxic footprint associated with improper solvent disposal. And, as brand owners increasingly prioritise sustainable practices, water washout technology resonates well with the market’s eco-conscious shift.
Yet, there’s more to this technology than just sustainability. When evaluating the economic side, water washout systems have some clear advantages. While the initial investment in specialised filtration and treatment equipment can be steep, the reduced operational expenses make it a sound choice. Zaheer explains that solvent-based set-ups require storage infrastructure and ventilation systems to manage harmful emissions, raising costs and adding regulatory layers. ‘Water washout systems, on the other hand, cut these requirements, making regulatory compliance simpler and less costly. Over time, businesses see savings in areas like waste management, health and safety fees and equipment maintenance.’
Flexing Flenex FW
Beyond cost-cutting, the speed and productivity gains from Fujifilm’s latest water washout technology are striking. The company’s Flenex FW plates are designed to dramatically cut down processing time without compromising quality, Zaheer reveals. ‘With an impressive processing time of under 40 minutes – around 300% faster than leading solvent-based systems – Flenex allows printers to hit tight deadlines with ease, amplifying production capacity and minimising bottlenecks,’ he enthuses. ‘Faster turnaround translates to fewer job delays, especially in high-volume environments where demand for on-the-spot production is high.’
Zaheer also highlights that water washout systems give companies the option to insource plate making, a feature that further expedites production by eliminating the lead time associated with outsourcing plates.
Energy and water efficiency also shine in the Flenex system. Its advanced filtration units enable water reuse multiple times before needing replacement, a move that substantially lowers water consumption. ‘Coupled with shorter drying times – under 10 minutes, compared to over an hour for solvent plates – Flenex FW offers tangible energy savings, crucial at a time when rising energy costs challenge profitability,’ he states.
Fujifilm goes a step further to ensure that customers feel fully supported through the transition from solvent to water washout. Zaheer explains that Fujifilm’s team provides a personalised set-up, tailored to each business’s workflow and space requirements. Technicians meticulously handle installation and equipment configuration, ensuring that each component – from washout units to drying systems – is optimised for seamless integration. By offering customised payment plans, Fujifilm helps companies manage upfront costs, easing the switch to a more environmentally responsible alternative.
The success stories from Fujifilm customers reinforce the advantages of this technology. Zaheer points to Aztec Label in the UK, which leveraged Flenex FW water-washable plates to meet customer demands for speed and quality. The company reported substantial time savings and operational efficiency, boosting its ability to deliver on fast turnarounds. As Colin Le Gresley, managing director of Aztec Label, puts it: ‘The Flenex trial was an instant success, immediately remedying the challenges we faced with solvents.’
The shift from solvent-based systems to water washout technology embodies the printing industry’s future. For flexographic printers, adopting water washout technology means more than just compliance with evolving environmental regulations – it’s a strategic move toward a faster, safer and greener production landscape.
