Number

022-EN

Section

General Section

Use

Abstract

Toxic chemicals found in printing inks based on organic solvents used for the printing of plastic shopping bags were replaced by water-based inks, which eliminated toluene and butan-1-ol from the printing process.

Substituted substances

Alternative Substances

Reliability of information

Evidence of implementation: there is evidence that the solution was implemented and in use at time of publication

Reason substitution

other toxic effects
ecotoxicity
physical hazards

Hazard Assessment

Toluene is toxic for the reproduction: Possible risk of harm to the unborn child (H361d). Also it is irritating to skin (H315) and its vapors may cause drowsiness and dizziness (H336). The substance may cause lung damage if swallowed (H304). There is a danger of serious damage to health by prolonged or repeated exposure through inhalation (H373). Also Toluene is highly flammable liquid and vapor (H225). Butan-1-ol vapor causes skin and respiratory system irritation (H315/ H335). Also it may cause drowsiness and dizziness (H336) and it is harmful if swallowed (H302). Also causes serious damage to the eyes (H318) The alternative substance 1-Methoxypropan-2-ol may cause drownsiness and dizziness (H336) and also is flammable liquid and vapor (H226). The alternative product must be handling with adequate measure protections. The alternative substances Ethanol is listed on the SDSC as group 1 carcinogen according to IARC. This entry applies however alcoholic beverages. » Check the Substance Database according to SUBSPORT Screening Criteria (SDSC)

Description of Substitution

This experience was carried out in a company that manufactured plastic bags. Toluene and butanol- based organic inks were used in the printing process. These chemicals are particularly harmful to human health and to the environment, especially toluene which is neurotoxic and toxic for reproduction.Complaints filed by union representatives resulted in the trade union’s occupational health department decision to take action with a proposal for the substitution of organic solvents with water-based inks. Water-based inks use water as solvent, and some alcohols and organic solvents are used as co-solvents. In the alternative product ethanol and 1-methoxypropan-2-ol are used as co-solvents.The substitution of inks allowed the replacement of other hazardous chemicals used in the cleaning of printing rolls, namely solvents. This experience is explained in case 023: Substitution of propan-2-ol, 2-methylpropan-1-ol and heptane in the cleaning of printing rolls.The company initially rejected the substitution suggested by the regional trade union’s health and safety department (CC.OO. Aragon) but a fire alarm took place in the area where solvent containers were stored. Given the nature of the solvent those containers represented a high risk of explosion and increased the possibility of a serious accident. These facts changed the managers’ views and forced them to accept a quick substitution. The company’s action was not so much a result of its intention to substitute a hazardous chemical as the consequence of eliminating the containers which represented a high risk of explosion. Propan-2-ol, 2-methylpropan-1-ol and heptane (used for the cleaning of printing rolls) were therefore replaced with ammonia, as explained in case 023.The company is also investigating the possibility of manufacturing potato starch bags. A research and preliminary production line based on this raw material is currently open and active.Starch-based bags would not require solvent inks. This was one more reason for the substitution of printing inks. Description of procedure or technology (including pre-/post-processing)The process follows the typical procedure of a plastic industry facility. The raw material used in the process is chaff distributed by other companies or recovered from the production line.The process starts with the extrusion of chaff, i.e.: turning of chaff into rolls of plastic film used for the manufacture of bags. Then the bags are printed and pressed into 25, 50, 75-bag bundles before they are finally packed for distribution.Inks are used in the printing process and solvents are used in the cleaning of printing rolls.For years the company had used RUBIFLEX series inks based on organic solvents (toluene and butan-1-ol). Those inks were replaced by IDROSTAR inks with a maximum concentration of 1-methoxypropan-2-ol lower than 2.5%.The company is currently developing a new line of manufacture of environmentally-friendly bags based on potato starch and printed with water-based inks.Way of application: e.g. spraying, dipping, open/closed system etc.Risk management measures (technical, organizational and personal)Risk reduction by alternative: Human health: e.g. more/less safety measures e.g. technical/operational/personal protection measuresReplacement of solvent-based paints. The health and safety of workers has been significantly improved.Risk reduction by alternative: Environment: e.g. waste reduced/increasedThe volume of hazardous wastes to be handled by specialized services has been reduced.

Case/substitution evaluation

Comments The replacement of hazardous inks by safer alternatives involved the substitution of hazardous solvents used for cleaning printing rollers as a positive collateral effect. This improved substantially the health and safety of workers. Advantage or Disadvantage of alternative

Aspect	Advantage/disadvantage to conventional process
Technical requirements
Implementation	Advantanges The most successful practice implemented by the management was the elimination of a 10,000-litre tank of solvent F-1. With the substitution inks the infrastructure for the distribution of solvents to clean the printing rolls was no longer necessary. This measure also avoided the exposure of workers to organic vapors. Disadvantages New inks are thicker and required more to achieve the exact mixture. A technical problem arose with ink injectors. The new inks required a bigger aperture of ink injectors into water. Injectors had to be drilled to achieve the desired size which implied a minimal investment. Additional comments The process revealed two aspects that influenced the company in favor of substitution: – The company had to comply with regulation on VOCs (compulsory provisions on vapors and emissions for all the companies which purchase a certain amount of organic chlorides). Compliance implied a full checkup of air extraction system. Substitution was a less expensive option. – The use of organic solvents is prohibited in the manufacture of bags that use potato starch as raw material. The regional trade union (CC.OO. Aragon) organized a series of information meetings to explain the difference between various types of ink and the hazards to human health of organic solvents and inks.
Operational expenses	The cost of facilities was also reduced since electric elements are no longer required to be explosion-proof and do not need to comply with ATEX Directive. The practice proves to be more profitable.
etc.

State of implementation

Full capacity

Date and place of implementation

2007 Spain

Enterprise using the alternative

www.sphere-spain.es

Availability ofAlternative

On the market

Producer/Provider

www.chimigraf.com

Type of information supplier

User

Contact

www.aragon-ccoo.es

Date, reviewed

February 27, 2020