How Water-Based Gravure Inks Lower VOC Emissions

The gravure printing industry has long relied on solvent-borne inks for their proven adhesion, wetting and rapid drying on non-porous films. However, solvent formulations release volatile organic compounds (VOCs) during printing and drying — VOCs that create environmental compliance burdens, worker-health risks and disposal costs.

Transitioning to water-based gravure inks is a technical and economic pathway that directly targets VOC emissions while enabling safer workplaces and helping brands meet stricter sustainability requirements.

Mechanisms of VOC reduction 

Water-based inks replace most hydrocarbon solvents with water and low-VOC coalescents or dispersants. Because the bulk carrier is non-volatile water, the measurable emissions of organic vapors during drying fall drastically — field conversions have recorded workshop VOC concentration reductions in the range of ~80–90% after switching and tuning presses to the new chemistry.

This reduction occurs for two reasons: the evaporation mass of organics is far smaller, and solvent-handling losses (mixing, fountain returns, cleaning) are minimized.

Benefits beyond emissions

Lower VOCs immediately reduce ventilation and compliance costs, decrease fire/explosion hazards, and improve shop-floor air quality (better worker health). Brand and consumer demand for low-VOC packaging also helps converters win environmentally conscious contracts.

In several documented conversions, companies have preserved or improved print appearance and throughput after a short commissioning period.

Important caveats 

Not all substrates and all gravure lines convert smoothly. Water-based systems sometimes require alcohol co-solvents for adhesion or more dryer energy if formulations are not optimized; a proper LCA and pilot testing are necessary so that VOC benefits aren’t offset by higher energy use or wastewater burdens.