A Case Study: Leveraging Thermal Inkjet Printing for Sustainability and Future-Proof Packaging

By  Pat Harnett, Director of Portfolio, Strategy & Development, HP

The packaging industry faces growing pressure to adopt sustainable practices due to heightened customer expectations and evolving regulations. Nearly half of U.S. consumers now prioritize sustainability in their purchasing decisions, pushing manufacturers to reassess the role and impact of packaging. In parallel, new global regulations, such as the EU’s sustainable packaging and waste directives, are driving the industry toward more environmentally responsible practices.

Digital Printing: A Driver of Sustainability

To meet these demands, the packaging industry is turning to digital printing technologies, which are essential for achieving sustainability goals and complying with regulatory requirements. Among these technologies, Thermal Inkjet (TIJ) stands out as a key enabler. TIJ offers precise, high-quality printing on various substrates, supporting the implementation of sustainable initiatives like the use of recycled materials, mono-material packaging and water-based inks. TIJ’s ability to print on demand and in smaller batches reduces overproduction and waste aligns with the principles of a circular economy. Printing directly on packages minimizes waste, streamlines production processes, and promotes using sustainable materials and inks, significantly reducing the environmental impact of packaging.

One success story that highlights the potential of TIJ technology comes from authorized HP Inkjet technology licensee, Loogal, and their customer, a Chinese sugar manufacturer. The manufacturer faced significant challenges in printing high-resolution track-and-trace QR codes on non-porous polypropylene (PP) sugar bags. Traditional Continuous Inkjet systems proved unreliable, leading to frequent downtime and costly repairs.

By adopting TIJ technology, Loogal overcame these challenges, achieving significant improvements in product quality, security, and production efficiency. The fast-drying, high-resolution printing capabilities of Loogal’s HP TIJ based printers allowed the manufacturer to meet stringent government regulations while minimizing costs.

Regulatory Compliance Driving Digital Transformation

One of the most significant shifts on the horizon is the GS1 Sunrise 2027 initiative. GS1 is set to transform the packaging industry by promoting a move from UPC/EAN barcodes to more advanced two-dimensional barcodes, such as data matrix and QR codes. In the EU, this shift will introduce Digital Product Passport (DPP), which provides consumers with detailed information about sustainability attributes, and the GS1 QR code will be a driver of the regulation. This added transparency is particularly valuable in industries like pharmaceuticals, nutraceuticals, and Fast-Moving Consumer Goods, where the ability to verify product authenticity and combat counterfeiting is critical.

As the industry adapts to these new standards and regulatory demands, TIJ technology will play an essential role in ensuring compliance. TIJ’s ability to handle variable data with precision allows for the consistent and accurate printing of crucial information, such as barcodes, expiration dates, and other identifiers. These readable codes are essential for channels, retailers and consumers.

The limitations of traditional one-dimensional barcodes in providing comprehensive product information have become increasingly apparent. As the GS1 Sunrise 2027 initiative progresses, the packaging industry will need to embrace these technological advancements to not only meet regulatory requirements but also to enhance product security, improve consumer trust, and ultimately lead the way in setting new global packaging standards.

The Future of Packaging with TIJ

TIJ technology is poised to play a critical role in the future of packaging. Beyond just meeting regulations, TIJ offers manufacturers the flexibility to innovate, adapting to emerging trends such as personalized packaging and on-demand production, which reduce waste and enhance efficiency. By embracing digital transformation and leveraging technologies like TIJ, the packaging industry can lead the way to a sustainable future.

About the Author

At the helm of HP’s Portfolio, Strategy & Development, Pat Harnett’s tenure has been marked by pioneering product lifecycle strategies and fostering innovation across the board. His team’s efforts have centered on propelling HP’s Thermal Inkjet Technology to the forefront of specialized markets, including coding and marking, inline packaging and life sciences, ensuring HP’s OEM partners are equipped with top-tier industrial print solutions. Learn more at: https://www.hp.com/us-en/specialty-printing-solutions.html