Case Study: StarColor Water-Based Flexographic Ink for French Fry Box Packaging

Date：2026-01-08 09:37:08  from：StarColor Ink  Views:

In Southeast Asia’s fast-food packaging market, environmental compliance, food-contact safety, and resistance to hot and humid climates have become key competitive factors. This case study highlights how Zhongzhixing’s food-grade water-based flexographic ink successfully upgraded the iconic red-and-yellow patterned French fry boxes of a well-known regional fast-food chain.

1. Background

In 2022, Thailand tightened its packaging printing VOC regulations, reducing the allowable VOC limit for solvent-based inks from 150 g/L to 50 g/L. As a result, many printers using solvent inks faced compliance risks, production suspension, or costly rectification.

French fry boxes come into direct contact with hot food. Residual solvents such as toluene and ethyl acetate from conventional solvent-based inks can migrate into food, posing safety risks. In one documented case, a batch of fry boxes was rejected for failing Thai FDA solvent residue limits, resulting in losses exceeding USD 2,800.

Additionally, Southeast Asia’s year-round high temperature (above 30°C) and humidity (≥75%) often cause color dullness and fading when inks are not climate-adapted, reducing brand recognition.

2. Solution

In 2021, the printing plant adopted Zhongzhixing food-grade water-based flexographic ink, developing a tailored solution for food-grade white paperboard, high-speed flexo printing, and humid climate resistance.

2.1 Food-Grade Formulation

• Compliant with Thai FDA and Philippine BFAD food-contact standards
• VOC content as low as 8 g/L, solvent residue ≤ 0.1 mg/dm²
• High-solids (42%) modified acrylic resin system with pigment particle size ~0.8 μm
• Color difference controlled within ΔE ≤ 0.8, ensuring sharp patterns and accurate brand colors

2.2 High-Speed Flexographic Performance

• Optimized for 300 LPI anilox rollers and printing pressure of 0.15 MPa
• Stable operation at 180 m/min, increasing daily output from 50,000 to 80,000 boxes
• Special humidity-resistant additives form a dense ink film after curing
• Tested at 35°C and 80% RH for 7 days with no bleeding or ink loss

2.3 Environmental Compliance

Thanks to ultra-low VOC emissions, the printer obtained Thailand’s “Green Packaging Supplier” certification without installing additional exhaust treatment systems, reducing annual environmental compliance costs by approximately USD 17,000.

3. Results

• Brand impact: Packaging approval ratings in Thai stores increased from 78% to 94%
• Manufacturing efficiency: Waste rate dropped from 5% to 0.3%, with a 30% productivity increase
• Business growth: Water-based flexo ink orders grew from 20% to 70% of total volume, driving annual revenue growth of 30%

4. Practical Guide for Southeast Asian Fast-Food Packaging

• Choose food-grade inks: Comply with local FDA standards; VOC ≤ 50 g/L
• Ensure humidity resistance: Use inks designed for hot and humid climates; ink film hardness ≥ HB
• Match high-speed flexo printing: Viscosity 15–30 s (DIN 4, 25°C) for 150–200 m/min production

Conclusion

As environmental regulations tighten and food packaging safety standards rise across Southeast Asia, water-based flexographic ink has become the optimal solution for fast-food packaging. This French fry box case demonstrates that selecting inks tailored to regional climate and regulatory requirements not only solves compliance challenges but also unlocks new growth opportunities in Southeast Asia’s packaging market.