How to Improve the Wear Resistance and Anti-Adhesion of Water-Based Gravure Ink

Water-based gravure inks have become increasingly popular in packaging, publishing, and decorative printing due to their low VOC emissions and environmental advantages. However, compared with solvent-based inks, water-based gravure inks face challenges such as lower wear resistance, poor slip, and adhesion issues during printing or stacking.

For high-speed gravure printing—especially in flexible packaging—these issues can cause scratches, blocking, and reduced print clarity, leading to customer complaints and increased production waste. So, how can formulators improve both wear resistance and anti-adhesion in water-based gravure inks? The solution often lies in the judicious use of wax additives.

Challenges in Water-Based Gravure Inks

1. Low Wear Resistance
   Due to the hydrophilic nature of water-based resins, dried ink films are often softer than solvent-based systems, making them more vulnerable to abrasion during transport and handling.

2. Blocking and Adhesion
   Freshly printed substrates stacked or rolled can stick together if surface slip is insufficient, causing smudging or ink transfer.

3. Surface Smoothness and Slip
   Without proper slip control, print surfaces may feel tacky, creating handling difficulties in high-speed packaging lines.

How Wax Additives Improve Performance

1. Enhanced Wear Resistance

   • Micronized polyethylene (PE) wax disperses evenly in water-based systems, forming a fine protective layer that resists scratching and rubbing.

   • Fischer-Tropsch (FT) wax with high hardness improves abrasion resistance, prolonging print durability.

2. Anti-Adhesion & Slip Control

   • Wax particles reduce surface tackiness by lowering the coefficient of friction, preventing sheets or films from sticking together.

   • PTFE-modified waxes further enhance slip, ensuring smooth handling and reduced blocking.

3. Gloss and Transparency Balance

   • Properly selected waxes improve surface properties without dulling colors or reducing transparency, which is crucial for premium packaging prints.

4. Stain and Chemical Resistance

   • Waxes enhance ink’s resistance against oils, solvents, and food stains, supporting long-lasting print quality.

A flexible packaging printer using water-based gravure inks for food pouches faced recurring issues with smudging and poor abrasion resistance during lamination. By incorporating micronized PE wax at optimized particle size, they achieved:

• 40% improvement in abrasion resistance during rub tests

• Significant reduction in blocking during film lamination

• Stable gloss levels with no negative impact on print clarity

This case demonstrates how fine-tuned wax additives can directly enhance ink performance in real-world applications.

Technical Insights for Formulators

• Particle Size Matters: Ultra-fine wax (<5 μm) ensures smooth surface films, while coarser particles provide anti-slip textures.

• Dispersion Quality: Good dispersion in water-based systems prevents aggregation and haze.

• Choice of Wax Type:

  • PE wax → balanced scratch resistance & slip

  • FT wax → high hardness for maximum wear protection

  • PTFE blends → ultimate slip and anti-blocking

Improving the wear resistance and anti-adhesion of water-based gravure inks is critical for meeting the performance demands of modern packaging and printing. Wax additives offer a proven solution by enhancing abrasion resistance, slip, and surface durability—all without sacrificing color or gloss.

If you are developing or upgrading water-based gravure inks, our specialized wax additive solutions can help you solve these challenges. Contact our technical team today for tailored recommendations and sample support to achieve the perfect balance of durability and print quality.