What is Waterless?

Waterless printing is an offset lithographic printing process that eliminates the water or dampening system used in conventional printing. It uses silicone rubber coated printing plates and specially formulated inks, and typically a temperature-control system is integrated into waterless presses.

In contrast to conventional printing, which is a chemical process that relies on isopropyl alcohol or substitutes, waterless printing is a mechanical process. The waterless press operator is not challenged with balancing the delicate relationship between ink and water. Waterless printing requires only an appropriate temperature range for transferring ink to substrate.

The waterless process offers several advantages vs. conventional printing, including better print quality measured in terms of color consistency, color saturation, detail reproduction and overall sharpness.

• Waterless also improves productivity by reducing makeready time and simplifying press operation
• Printing job times are shortened by 9%
• Productivity gain through increased capacity
• Makereadies are 18% faster than with conventional printing.

The environmental benefits of waterless printing have captured the attention of printers and print buyers alike. The process eliminates fountain solution, which eliminates the consumption of water and significantly reduces the release of volatile organic compounds (VOCs) into the atmosphere vs. conventional printing.

60% of VOCs in offset printing come from washing solvent, with ink and fountain solution contributing 40%. A reduction in washing solvent VOCs is critical for small to mid-size printers to make meaningful VOC reductions. Waterless printing makes that possible.

Waterless operations using water washable ink systems are pushing the low-VOC scenario even further, with the potential to reduce VOC emissions up to 95% vs. conventional printing.

Reducing or eliminating VOCs benefits not only the planet, but also the people working in the pressroom. These chemicals demonstrate an array of health effects, ranging from eye irritation to leukemia. The Department of Health and Human Services (DHHS) has determined that benzene, as an example, causes cancer in humans.

The critical need for water conservation, which is gradually gaining awareness even in developed countries, is a highly attractive environmental benefit of waterless printing. In a BBC report, the United Nations warned that more than 2.7 billion people will face severe water shortages by 2025 if the world continues to consume water at the current rate.

Printing has historically been a leading industrial consumer of water. According to data supplied by JL Lennard, a single five-six-color, 40 inch (102 cm) conventional printing press operating only one shift can use 3,175 gallons (12,019 liters) of water per year. An eight-unit 38” (96.5 cm) heatset web press will generate around 23,810 gallons (90,131 liters) per year. Some conventional web presses require more than 25,000 gallons monthly, which is enough water to overflow a swimming pool measuring 18 x 36 feet.

Waterless printing addresses the dilemma. A leading waterless printer has recently calculated that printing 10,000 copies of a simple direct-mail flyer using waterless printing and recycled paper would save enough water to support a human being for a year.

The final environmental advantage of waterless printing is reduced paper waste. Because waterless presses come up to color and register so much faster than conventional equipment, paper savings of 30% to 40% have been reported. Consequently, the burden on the waste stream is lessened—and fewer trees need to fall.
The combination of natural resource conservation, reduced air and water pollution, high print quality, productivity gains, and employee wellness position waterless printing as a robust and appropriate technology for the twenty-first century.

For more details about how we can save you money through waterless printing, please contact us 01202 576266, or sales@premierprint.co.uk