Cleaner production of flexographic ink by substituting carbon black with biochar

Abstract

There is growing interest in making printing inks more sustainable, and lowering the overall carbon footprint of the printing industry. A recent surge of research activity has emerged to develop “green” inks with bio-based solvents and binders, but little attention has been given to replacing the pigments that give inks their distinctive color. In this study, flexographic inks were formulated by replacing carbon black with a more sustainable biochar pigment derived from recycled paper, and fast growth cycle wood pulp. Obtained from fossil fuel sources, carbon black imparts high quality black prints, but at a significant environmental cost. Biochar, derived from recycled and renewable resources, has the potential to replace carbon black in many applications. Canceled United States currency stock was pyrolyzed at 1600 °C to produce a black biochar. Eastern White Pine (Pinus strobus) was selected for comparison, and converted to biochar at 550 °C and 1600 °C. Each biochar was functionalized and formulated into a simple ink composition optimized for flexographic printing. Prints exhibiting reflective optical densities exceeding 1.0 with excellent tone reproduction were obtained. Comparable print quality was achieved on both coated and uncoated paper substrates. Although further work would be required to fully optimize a biochar ink to match current print industry standards, a viable pathway for sustainable black ink development with good black density derived from recycled resources has been demonstrated. Our results indicate that it is possible to replace fossil fuel-based carbon black with biomass derived biochar, potentially resulting in cleaner production of flexographic printing inks.