WATER-BASED INKJET FOR PACKAGING

Inkjet printing for packaging is undergoing a decisive technological transition. This is driven by increasingly stringent regulatory frameworks, ambitious sustainability targets and the growing complexity of packaging substrates. As a result, the industry is re-evaluating long-established printing architectures. At the centre of this evolution is the accelerating adoption of water-based inkjet systems. These systems are moving beyond pilot projects and into industrial-scale production environments.

Today’s inkjet inks are required to deliver far more than colour strength and jetting stability. They must comply with evolving chemical regulations, support low-migration and food-safe applications. In addition, inkjet inks need to enable efficient production across a wide variety of absorbent and non-absorbent substrates. These requirements are reshaping how inkjet systems are designed, developed and deployed – shifting the focus from individual components, towards fully integrated printing ecosystems.

Most industrial, water-based inkjet platforms are built around four-colour (CMYK) architectures. However, the increasing demand for brand-critical colour reproduction is driving the addition of spot colours and extended gamut inks, such as orange, green and violet (OGV). This enables a broader colour space without reverting to analogue processes. In turn, supporting shorter runs and faster changeovers.

In packaging, water-based inkjet solutions are rarely off-the-shelf products. Instead, they are project-driven systems, tailored to specific applications and production constraints. Critical adaptation parameters include substrate type, printhead technology, drying capacity and mechanical-performance requirements. These include abrasion resistance and flexibility. Regulatory compliance – particularly future-proof, carcinogenic, mutagenic or reproductive (CMR)-free formulations – is now a baseline expectation, rather than a differentiator.

To manage this complexity, modern inkjet development relies heavily on modular ink and primer platforms. These allow chemistries to be fine-tuned for individual presses, workflows and end-use requirements.

“Water-based inks offer inherent advantages”

One of the defining technical challenges of aqueous inkjet is its interaction with different substrates. On absorbent materials, such as paper or corrugated board, water can be drawn into the substrate and removed relatively easily with thermal assistance. However, on non-absorbent materials, such as polymer films, the lack of porosity fundamentally changes the drying equation.

This has elevated inkjet primers from optional accessories to critical system components. Primers act as functional interlayers, providing a microporous structure that absorbs the water carrier while anchoring pigments at the surface. Well-designed primer systems improve adhesion, enable faster drying and reduce the thermal load required downstream. This is an essential consideration when printing on heat-sensitive films.

Primer chemistry has therefore become tightly linked to both ink formulation and dryer design, reinforcing the need for system-level optimisation.

The growing interest in water-based inkjet is being driven by a convergence of regulatory, environmental and commercial pressures. Brand owners – particularly in food, beverage and consumer packaging – are increasingly demanding solutions that minimise migration risk and reduce chemical exposure. Water-based inks offer inherent advantages in this regard, especially for applications involving indirect or direct food contact.

Sustainability is an equally powerful driver. Compared to UV-curable systems, water-based inks typically offer a lower carbon footprint. This is because these inks reduce the reliance on fossil-derived raw materials and enable thinner ink layers. When combined with efficient drying systems, converters can significantly reduce energy consumption per printed unit. This is an increasingly important metric as environmental reporting becomes more rigorous.

As global brands commit to long-term sustainability strategies – including net-zero targets – water-based inkjet is shifting from an alternative technology to a strategic necessity.

Despite its advantages, aqueous inkjet presents one of the most complex engineering challenges in industrial printing – the drying dilemma.

The conflict is fundamental. On the substrate, ink must dry rapidly to prevent set-off, enable rewinding and maintain line speed. In the printhead, however, the same ink must remain wet at all times to avoid nozzle clogging, misfiring and latency issues. If an ink dries too quickly, it risks forming a skin at the nozzle face during even brief pauses. If too many humectants are added to keep nozzles open, drying on non-porous substrates becomes highly energy intensive.

Addressing this challenge requires a co-ordinated, three-pronged approach. Firstly, advanced ink chemistry, using binders with controlled re-solubility that can temporarily skin over, yet re-dissolve during jetting. Secondly, printhead architecture, particularly nozzle-level recirculation systems that keep ink in constant motion and reduce stagnation. Thirdly, drying engineering, combining hot air and infrared technologies to efficiently remove water from primer layers without damaging substrates.

No single component can resolve the drying dilemma in isolation. Success depends, therefore, on optimising the entire system.

“Siegwerk delivers tailored, water-based inkjet solutions”

As performance requirements tighten, the concept of a universal, drop-in ink is no longer viable – especially for packaging applications. The tolerances involved are simply too narrow.

Instead, industrial water-based inkjet increasingly relies on co-development between ink suppliers, original equipment manufacturers (OEMs) and system integrators. Ink rheology must be matched to specific printhead waveforms and recirculation rates. Primer chemistry must align with available drying capacity and substrate characteristics. Hardware, software and consumables must be engineered as a unified ecosystem.

In this environment, ink suppliers are evolving from material vendors into technology partners, contributing directly to system architecture, optimisation and long-term reliability.

Demand for water-based inkjet systems is expected to grow significantly in the coming years. Stricter regulations, sustainability commitments and the expansion of direct food contact (DFC) applications are accelerating adoption. UV-based systems face inherent challenges in these areas due to migration-critical components, such as photo-initiators. In contrast, water-based alternatives offer clearer compliance pathways.

At the same time, the diversity of packaging substrates continues to expand, driving further differentiation in ink and primer formulations. Investment in research, testing and application-specific development will be essential to meet these evolving demands.

The shift toward water-based inkjet is not simply a technological upgrade – it represents a fundamental change in how packaging-print systems are conceived, validated and operated.

Water-based inkjet technology is moving from early adoption towards mainstream industrial deployment. As a result, the importance of deep technical expertise and close collaboration across the value chain becomes increasingly clear. Siegwerk is one of the world’s leading developers and manufacturers of printing inks. The company brings more than two centuries of formulation, manufacturing and application knowledge to this transformation. Siegwerk’s experience spans both established analogue processes and advanced digital technologies. This means that the company is well positioned as a strategic partner for the packaging and printing industry.

Through sustained investment in research and development, Siegwerk delivers tailored, water-based inkjet solutions designed specifically for OEMs and system integrators. The company addresses the complex interactions between ink chemistry, printheads, substrates, primers and drying systems. Thus market-ready solutions are enabled that meet today’s demanding regulatory, sustainability and performance requirements.

The industry-wide shift towards water-based inkjet is not merely a technological evolution. It is also a strategic response to regulatory and ecological challenges. For converters and brand owners alike, adoption is increasingly becoming a necessity rather than an option. By combining long-standing expertise with cutting-edge innovation, Siegwerk is actively shaping this transition. The business is working hand in hand with OEMs and integrators to build adaptable, future-ready inkjet systems that will define the next generation of sustainable packaging printing.