Why solvent-free has never mattered more for the flexo printing industry

The global supply chain has faced multiple major disruptions in recent years, but the recent and ongoing (at the time of writing) closure of the Strait of Hormuz stands in a category of its own.

Widely regarded as the most significant disruption to the world energy supply chain since the 1970s oil crisis, and regarded as the largest single shock in the history of the global oil market, the consequences of the closure of this critical waterway for global supply chains have been felt across consumer and business markets. From rising prices at the petrol pump and the threat of jet fuel shortages disrupting summer 2026 holidays, to the tight supplies of essential raw materials for manufacturing, it’s had a very real impact.

Specifically for the label and packaging print industry, the knock-on effect on solvent prices has been sharp, sustained, and, for those still dependent on traditional platemaking processes, an uncomfortable challenge.

A vulnerability, hidden in plain sight

For decades, solvent-based washout has been the standard method for processing photopolymer flexo plates. It has worked well, it is understood, and the cost of the chemicals involved has been broadly predictable.

What the current geopolitical climate has made clear is that predictability relied on stable energy markets and uninterrupted global supply chains. It is fair to state that today, neither of those conditions can be taken for granted.

When the flow of raw materials is disrupted and choke points are exploited for geopolitical leverage, manufacturers are hit hard. This is exactly what has happened with the closure of the Strait of Hormuz, through which a significant proportion of the world’s oil flows. As it became inaccessible, crude oil prices skyrocketed and a predictable market has become extremely volatile. Political brinksmanship and continued talk of a resolution to the conflict has exacerbated the situation as a result of threats, counterthreats, and false dawns.

With solvents derived from petrochemical processes directly exposed to crude oil price movements, flexo industry suppliers have faced the challenge of passing higher costs on to their customers or absorbing them and eroding margins. Either situation is at best uncomfortable and at worst, untenable.

Thanks to our long-standing commitment to going solvent-free, Creation’s customers have largely been sheltered from these cost challenges and price increases. Our prices have remained stable and predictable throughout the current situation.

A commitment made early, now vindicated

We have been solvent-free from the very beginning, always driven by environmental conviction and the desire to push practices deeper into the supply chain. This involved a clear commitment to not use solvent plate materials and solely rely on sustainable, water-washable alternatives. That initial decision taken with long-term responsibility in mind has proven to be commercially astute as well.

The principle behind solvent-free flexo pre-press is straightforward. Water-washable flexo plate technology eliminates volatile organic compounds (VOCs) from the platemaking process entirely. Rather than using chemical solvents to wash out the unexposed areas of the photopolymer plate, the process uses water. The result is a cleaner working environment, a substantially reduced carbon footprint, and a production process that is not directly exposed to petrochemical price fluctuations.

Specifically, Fujifilm’s Flenex FP water-washable flexo plate technology is driving this change today at Creation Reprographics.

Flenex FP is a water-washable flexo plate that provides the highest print quality and productivity, while significantly lowering the cost-in-use compared to thermal, solvent or other water-wash plate technologies.

These plates contain a special rubber-based compound that offers a number of inherent advantages over other elastomeric materials from which most other flexo plates are made. Moreover, Flenex FP water-washable plates reduce platemaking processing times to less than 40 minutes, which is as much as 300% faster than leading solvent systems and 1.5 times faster than competitive thermal and water-wash technologies.

This technology is central to our plate production process and has demonstrated that there is no compromise in going solvent-free; print quality, registration accuracy, and on-press performance fully maintained.

With the conversation pivoting to cost and supply chain challenges, solvent-free pre-press has shown itself again to be the optimum choice for the future of flexo printing.

What this means in reality

Water washable flexo plates offer a compelling combination of environmental and commercial advantages that make them an increasingly attractive choice for modern flexo print operations.

Unlike solvent-based plates, which require harsh chemicals for processing and generate hazardous waste that demands careful disposal, water washable plates use water as the washout medium, dramatically reducing VOC emissions and eliminating the need for costly solvent recovery or disposal systems.

This cleaner process translates directly into lower regulatory compliance burdens and a reduced environmental footprint, which is a growing priority for brands and converters under pressure to meet sustainability targets.

Switching water washable flexo plates also makes a meaningful contribution to a printer’s emissions reporting. At Scope 1 level, which covers direct emissions from activities an organisation owns or controls, eliminating solvent-based plate processing removes a direct source of VOC and greenhouse gas emissions from the pressroom itself.

Scope 2 captures indirect emissions from purchased energy and since water washable systems typically require less energy-intensive processing than solvent alternatives, they can contribute to a lower energy consumption figure.

The biggest opportunity, however, lies at Scope 3, where the impact of indirect emissions that occur across a company’s entire value chain, including those associated with its suppliers, are felt.

By sourcing water washable plates from their repro partner, printers reduce the embedded emissions in the goods they purchase. This can account for up to 90% of a company’s total emissions.

Having a holistic overview of emissions is important as brand owners and converters are increasingly scrutinising their entire supply chains and the reporting of emissions across the whole supply chain, down to Scope 3, is starting to be mandated.

In short, choosing water washable plates is not just an environmental gain, it’s a quantifiable improvement that helps demonstrate supply chain sustainability credentials to customers who are under growing pressure to report and reduce their own value chain emissions.

Commercially, the elimination of solvents cuts consumable costs and removes the operational overhead associated with solvent handling, ventilation, and safety protocols.

As already noted, plate processing times are also faster, improving press-room throughput and reducing time-to-press.

As brand owners and retailers increasingly scrutinise the environmental credentials of their supply chains, offering water washable plate technology fulfils a genuine need in the market and helps print businesses win and retain customers who place sustainability at the heart of their procurement decisions.

On a practical level, the cost of producing a flexo plate at Creation is not tied to the price of crude oil. It is not exposed to shipping disruptions in the Gulf Region, sanctions affecting petrochemical trade, or the downstream pricing pressures that solvent-dependent suppliers are currently navigating. Creation’s plate prices have remained consistent, and they are positioned to stay that way.

For label and packaging printers managing tight margins and customer relationships that depend on cost predictability, this matters. A pre-press partner whose pricing is buffered from geopolitical volatility is not only convenient but is a genuine commercial advantage.

What this means operationally to the flexo printing industry is that supply chain disruptions resulting from situations such as the closure of the Strait of Hormuz need not be such a business risk.

The case for solvent-free flexo plate production was already compelling on sustainability grounds. The current world situation makes it equally compelling on commercial and operational grounds.

With Creation Reprographics having a long-standing commitment to going solvent-free, this is now demonstrating inherent value to the flexo industry.

For any packaging and label printer still working with a solvent-dependent pre-press partner, the question to ask is a simple one: what happens to your costs the next time the market is disrupted?

To find out more about Creation’s solvent-free flexo plate production and pre-press services, contact our team here.