Japan: more inclined to develop waterless printing technology

In the early 1960s, the U.S. company 3M pioneered the development of waterless offset printing technology and brought it to industrial production. Waterless printing is a green and eco-friendly method of offset printing, but its high costs for plates and inks have historically limited its widespread adoption by printing companies. In May 2012, Chengdu Xintu New Materials Co., Ltd. officially partnered with Toray Japan to begin the comprehensive promotion and sale of waterless offset plates in China. To gain deeper insight into the current state and future potential of waterless offset printing, the author had an exclusive interview with Mr. Toshihiro Matsumoto, Sales Director of Toray’s Printing Systems Division, at the ChinaPrint 2013 exhibition. Below are the key highlights from the conversation: Q1: It is known that Toray Japan started selling waterless offset plates in the mid-1970s. What was the situation with waterless printing back then, and how did Toray perform in sales? Matsumoto: Toray Japan began producing and selling waterless offset plates in 1979. At that time, the technology was still in its early stages, and the necessary materials—such as special inks and cooling systems for printing presses—required significant time and effort to develop. As a result, official sales only began in Japan in 1990, followed by expansion into Europe and other international markets. Q2: Over the past 30 years of the 20th century, what progress has been made in waterless offset printing? And in the first 10 years of the 21st century, what do you see as the biggest breakthrough? Matsumoto: The most significant development has been the improvement of silicone coatings with excellent ink resistance, which is essential for waterless printing. Toray's extensive experience in silicone technology helped accelerate these advancements. Additionally, our expertise in polymer chemistry played a key role. We also developed unique coating technologies and collaborated with ink manufacturers to create specialized inks. Printing machine manufacturers, like KBA, introduced machines with cooling functions, making waterless printing more stable and efficient. Over the past decade, waterless printing has significantly reduced the use of fountain solutions and improved workshop environments, contributing greatly to environmental protection. Q3: How does the promotion of waterless printing differ between other regions and Japan today? What do you think are the reasons behind these differences? Matsumoto: Japan leads in market penetration due to early investment and long-term efforts. However, overseas markets, especially in Europe, have also seen strong growth, driven by environmental awareness. KBA, one of the oldest printing press manufacturers, developed dedicated waterless printing machines, which boosted sales in Europe. Now, we’re focusing on China, the world’s largest printing market, where we expect rapid growth. Q4: Last year, there was news that Toray started building a new plate material factory in the Czech Republic. What is the current status of this project, and why was the Czech Republic chosen over other countries? Matsumoto: The factory is under construction and expected to start operations in November this year. It was chosen to meet growing European demand and to utilize existing Toray facilities and workforce. We also plan to build a plant in China to support the expanding market. This will help us establish a global manufacturing network across Japan, Europe, and China. Q5: In Toray’s global strategy, Japan, Europe, and China are the three main markets. What is the current sales ratio in these regions, and which one is your favorite? Matsumoto: Currently, sales are approximately 40% in Japan, 40% in Europe, and 7% in China. While Japan and Europe remain the main markets, we are very optimistic about China’s future potential. Q6: Can traditional offset presses be easily converted to waterless printing? Are there any issues with adaptability or stability after conversion? Matsumoto: Yes, as long as the press has a temperature control system, it can be adapted for waterless printing. Special inks and equipment are also required, but if the right conditions are met, the transition is smooth. Most modern presses already have thermostats, making the switch easier. Q7: Is the number of factories switching from traditional to waterless printing increasing? What motivates them, and what are the benefits? Matsumoto: More customers are moving toward waterless printing. Benefits include environmental advantages, reduced paper damage, and increased efficiency. It’s particularly popular in UV packaging and non-absorbent materials like PP, PET, and PVC. Q8: Despite its potential, water-based printing still dominates the market. When do you think waterless printing will reach similar levels? What is your view on its future? Matsumoto: Water-based printing is still dominant now, but I believe its market share will shrink over time. As waterless technology becomes more mature, it will eventually become the standard. With rising environmental awareness in China, the chances of waterless printing becoming the mainstream are higher. Toray will continue to support this transition and drive market growth.

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