Reducing carbon emissions: advanced techniques for efficient return ink management in packaging printing

Packaging printers are under increasing pressure to measure and reduce their environmental impact. Reusing press return inks left over from a print job is an effective strategy for lowering carbon emissions, as highlighted in our blog about sustainable packaging.

There are three primary methods for incorporating leftover inks into new dispensing jobs:

In this blog, we will delve into advanced techniques to make the above methods even more efficient. This involves optimizing the weighing, recording and preparation of return inks.

Optimizing weighing and recording of return inks

The initial step in all methods involves registering the returns at the end of a print run. Typically, this is done by manually weighing the individual containers on the dispensing system’s scale. To optimize this process, installing GSE Return ink management software and a label printer and barcode scanner is essential.

The “cart weighing” function in the software boosts the efficiency of the weighing process by allowing operators to handle multiple return containers at once. These containers can be placed on a cart, pallet, or stacked together on the dispenser’s scale for weighing. The operator then scans each container’s unique barcode as they are removed one by one, while the software logs each container into the returns storage. A new label is printed with details such as the formula code, container ID, and return ink weight, which is then applied to the container. All the containers can then be stored at the designated location in a single step.

If the dispenser is equipped with an automatic infeed conveyor, the weighing process can be automated further. Once the machine is switched from dispensing to return weighing mode, all return containers are placed on the infeed conveyor. Each container is automatically transported to the weigh station, where it is weighed. The container ID is then scanned, and a new label is printed and applied manually. The container is then conveyed away without being mixed, even if an automatic mixer is present. This cycle continues until all containers are processed, and afterwards, they can be moved to the return ink storage area.

Preparing return inks

Containers can be prepared using returns for specific jobs scheduled in the job list. To prepare a return, first select the container from the job list and use the ‘Prepare Returns’ option to choose the appropriate return container, which should then be retrieved from storage. The return is weighed on the dispenser’s scale. Once weighed, a dispense label is generated, indicating that the container is incomplete and fresh inks have not yet been added.

Each container is then filled with the correct fresh inks required to complete the order. To ensure accurate job fulfilment, the operator must line up the containers are filled in the order of the job list.

If the dispenser features an automatic infeed conveyor, this process can made simpler by placing all prepared containers on the conveyor system and running the machine in automatic mode to complete all jobs.

Reserving return inks

Before dispensing begins, returns can be assigned to a job – such as one that uses the same colour – by simply checking the “reserved” box. This marks the return as reserved for that specific job. This process streamlines the operator’s work by removing the need to decide whether to use returns and which ones to select.

Installing a return weighing station

For many printers, adding a dedicated return weighing station that connects to Ink manager’s database can be beneficial for weighing and preparing return inks. This station ensures that the dispenser’s full capacity can be utilized exclusively for dispensing, while the weighing can take place at another convenient location, such as near the press or the return ink storage area. If the dispenser lacks the capability for “cart weighing” larger loads, a return weighing station with a high-capacity scale can serve as an effective solution.

Towards a circular economy

Adopting these advanced return ink management techniques can significantly enhance the sustainability of packaging printing operations. By optimizing the use of leftover inks, companies can minimize waste, reduce carbon emissions, and lower material costs, all while meeting the growing demands for environmental responsibility. Efficient weighing, recording, and preparing of returns not only streamlines production but also strengthens a printer’s commitment to a circular economy.

Take the next step toward sustainable printing practices. Explore how GSE Return ink management software can help you integrate these methods seamlessly into your operations and achieve your sustainability goals.

Sign up here to receive regular updates on this blog series for more insights on sustainable packaging and ink management. Or reach out to one of our experts, on email info@gsedispensing.com or telephone +31 575 568 080.