This method excels in high-speed printing applications, particularly on non-porous substrates such as plastics and metals, making it a go-to choice for decorating cylindrical objects like cans, tubes, and pails.

Zeller+Gmelin has been at the forefront of the dry offset printing industry, offering high-performance inks designed for precision and vibrancy across a wide range of applications

Understanding Dry Offset Printing

How Does it Work?

Dry offset printing uses a set of printing plates mounted on a rotating cylinder. These plates transfer ink to a rubber blanket, which then directly applies the ink to the substrate. Because there is no dampening process, dry offset relies on carefully engineered inks to achieve excellent adhesion and color fidelity.

How is it Different from Traditional Lithography?

While both processes utilize the basic principle of indirect ink transfer, hence the term “offset”, the absence of water in dry offset eliminates issues like emulsification and ink/water balance. This makes dry offset ideal for substrates that are water-sensitive or challenging to print on, such as plastics, foils, and metals. 

Equipment Used in Dry Offset Printing

Dry offset printing requires specialized machinery designed for speed and precision. Key components include:

Printing Plate: Typically made of metal or polymer, these plates are durable and suited for high-volume printing.

Blanket Cylinders: Essential for transferring ink uniformly to the substrate.

Inking Systems: Advanced inking units ensure consistent application across colors, critical for multi-color jobs.

Substrate Handling Systems: Designed for smooth feeding of cylindrical or irregularly shaped items.

Zeller+Gmelin’s inks are formulated to perform seamlessly with leading dry offset equipment, ensuring reliability and quality in every print run.

Applications and Substrates

Dry offset printing is widely used in industries where durability, precision, and efficiency are paramount. Common applications include:

Packaging: Printed designs on tubes, containers, pails, and bottle caps.

Beverage Cans: Eye-catching designs on soda and beer cans.

Promotional Items: Branded pens, keychains, and more.

Plastic Cards: Custom printed cards such as credit cards and hotel keys.

The versatility of dry offset lies in its ability to handle challenging substrates with precision printing.

Advantages and Limitations of Dry Offset Printing

Advantages

• High-Speed Printing: Capable of handling large volumes with minimal downtime.
• Vibrant Colors: Achieves high-quality, sharp prints with excellent ink adhesion.
• Cost-Efficient: Suitable for mass production, reducing per-unit costs.
• Eco-Friendly Options: Recent advancements like Zeller+Gmelin’s EarthPrint inks provide sustainable solutions for plastic packaging, without compromising performance.

Limitations

• Setup Time: Initial setup requires precision and attention to detail, requiring more time that some other print methods.
• Specific Substrate Compatibility: While versatile, it may not be ideal for porous materials like paper or fabric.

EarthPrint Technology: Advancing Dry Offset Printing

Zeller+Gmelin’s EarthPrint technology represents a leap forward in sustainable printing for plastic products and packaging. These eco-friendly inks are designed to effectively wash off for full product recyclability, while delivering the vibrant, durable results that dry offset printing demands. Whether you’re decorating pails and containers or creating custom packaging, EarthPrint inks offer a balance of quality and responsibility.

View the EarthPrint Infographic and Blog for more information on de-inking properties and recyclability.

Are you ready to elevate your printing process with high-performance dry offset inks? Contact Zeller+Gmelin today to learn more about our range of solutions, including our innovative EarthPrint technology. Let us help you achieve unparalleled results in your next printing project.

The post What is Dry Offset Printing? first appeared on Zeller + Gmelin.

RICHMOND, VA, November, 2025 – Zeller+Gmelin North America, manufacturer and innovator of printing inks and coatings, is pleased to announce the expansion of their successful EarthPrint ink product line, with the new UV/LED 79 Series. EarthPrint 79 Series is dual-cure, low migration, and designed for dry offset printing on rigid plastics such as cups, lids, buckets and other preformed containers.

EarthPrint ink solutions have proven successful in maintaining color brilliance and adhesion, while enhanced wash-off capabilities help brands and printers meet recyclability goals for sustainable plastics. That success continues with this new addition to their eco-friendly product line. The 79 Series is designed as a press-ready ink for printing vivid color shades. Capable of printing at high press speeds and rapid curing, it offers excellent adhesion, high gloss and transparency, and many other benefits. It is suitable for injected, extruded, thermoformed, and blow-molded preformed containers made from common plastic substrates.

“EarthPrint has been a highly successful product line for Zeller+Gmelin North America, leading the way in sustainable solutions for plastics,” said Tim Smith, Z+G Rigid Plastics Business Manager. “We are excited to expand our eco-friendly portfolio with the new 79 Series and continue advancing our ink wash-off capabilities. With our well-established 71 through 78 product lines already trusted by customers, we anticipate the 79 Series will see similar success.”

Zeller+Gmelin R&D Technicians developed and tested EarthPrint in strict compliance with Association of Plastic Recycling (APR) standards to ensure maximum recyclability. By using these eco-conscious inks, printers help advance packaging sustainability with cleaner, brighter plastics that require less raw materials and reduce plastic production.

Converters are invited to contact a Zeller+Gmelin Account Manager to discuss their print processes prior to ordering the new ink solution. Sales contacts and informational brochures are available on the company website at www.zeller-gmelin.us. To discuss Zeller+ Gmelin’s printing ink and coating solutions, please contact 804-275-8486 or submit a message online at www.zeller-gmelin.us/contact.  

Download the brochure, here.

The post Zeller+Gmelin expands its EarthPrint™ Inks with New Dry Offset 79 Series first appeared on Zeller + Gmelin.

Whether you’re running water-based or UV/LED inks, heat and humidity have a direct effect on performance, from ink adhesion to substrate handling. Below, we dive into three key challenges that surface in the summer months—and our expert’s recommendations to help you beat the heat.

Humidity Hazards in Ink Transfer and Adhesion

There are two ways that humidity can disrupt your print performance. The obvious one is muggy conditions in shops with no climate control. But even if you’re beating the heat inside with air conditioning and de-humidifiers, as you bring in your rolls of material from delivery trucks outside and place them on your shop floor, you may be facing some condensation issues—especially if those materials are placed directly on press without having time to adjust to the new ambient temperature.

No matter how humidity is being introduced to your print process, it can lead to a decrease in the surface energy of your substrate leading to poor ink adhesion, mottling, or other ink laydown issues. Avoid quality inconsistencies and material waste due to humidity by taking some precautionary steps in your operations. 

What to do

If possible, aim to keep your pressroom conditions at 45–55% relative humidity and under 75°F.

Don’t leave rolls on trucks or in loading bays during peak heat.

Allow substrates time to cool after being delivered.

Test your substrate with dyne pens before press runs and utilize a corona treater when needed.

Summer-Proof Your Storage

The pressroom isn’t the only area that suffers in the summer. Substrates stored in hot, unventilated warehouses can degrade quickly. Pressure-sensitive label rolls exposed to excessive heat may experience adhesive bleed, edge ooze, or even roll telescoping. Shrink films stored above 90°F can warp and distort from the heat, affecting registration and print quality.

What to do

Store sensitive substrates below 80°F in low-humidity rooms.

Rotate inventory using FIFO—older stock will degrade faster in hot conditions.

Store label stock vertically when possible to reduce adhesive pressure on roll edges.

Consider investing in insulated storage or HVAC upgrades for warehouse spaces.

Beat the Heat with UV/LED Curing

Traditional mercury vapor curing lamps emit a lot of infrared heat, raising web temperatures significantly. This only exacerbates heat-related issues during the summer months, which is especially problematic for label stocks, where heat can soften pressure-sensitive adhesives, or prematurely distort shrink films.

By contrast, UV and LED technologies cure at much lower web temperatures, helping printers maintain substrate integrity even on the hottest days. Beyond just label compatibility, UV/LED systems also reduce the need for heavy ventilation and climate control, lowering air conditioning costs and reducing pressroom energy consumption.

What to do

If you’re already considering making the switch to UV/LED curing technology, this could be an added benefit. Ask your press manufacturer or lamp supplier for more detailed cost savings projections to understand your potential ROI.

Summer Success with Smart Printing Practices

While you can’t change the weather, you can adapt your processes to maintain quality and performance all summer long. By understanding how heat and humidity affect your substrates, inks, and equipment—and by investing in temperature-friendly technology like UV/LED curing systems—you’ll be better equipped to handle seasonal variability without sacrificing consistency.

Zeller+Gmelin has decades of experience formulating high-performance UV and LED ink systems specifically designed for label and packaging printers who demand stability, efficiency, and brilliant results—even in the toughest pressroom conditions. Whether you’re facing ink transfer challenges or planning a shift to low-temperature curing, our team is here to help.

Contact your local Zeller+Gmelin representative to learn how our UV/LED ink solutions can support your operation this summer—and beyond.

The post Surviving Summer in the Pressroom: How to Protect Ink Adhesion and Label Quality first appeared on Zeller + Gmelin.

As experts in formulating compliant UV/LED inks, coatings and adhesives, we’ve put together this FAQ to break down the essentials of Prop 65—so you can focus on your business, not the fine print.

1. What Is Prop 65?

Proposition 65, formally known as the Safe Drinking Water and Toxic Enforcement Act of 1986, is a California law designed to safeguard residents from exposure to chemicals linked to cancer, birth defects, or reproductive harm. It mandates that businesses provide warnings if their products contain significant levels of these substances, such as lead, phthalates, or formaldehyde.

2. Who Must Comply with Prop 65?

Compliance is required for any business selling or distributing products in California, or manufacturing items that may reach California residents—including those based outside the state. This applies to business owners, printers, and compliance managers in the print and packaging sector. Exemptions exist for companies with fewer than 10 employees or products with chemical levels below designated “safe harbor” thresholds.

3. Which Chemicals Are Covered?

The Prop 65 list started with 30 chemicals in 1986 and now tops 1,000, all identified as potential carcinogens or reproductive toxins, with new chemicals added to the list every year. It includes substances that affect print and packaging manufacturers such as heavy metals, phthalates, bisphenol A (BPA), styrene, and certain solvents used in inks, coatings, and adhesives. View the full chemical list on the OEHHA website: https://oehha.ca.gov/proposition-65/proposition-65-list

4. When Is a Warning Required?

A warning is necessary when a product exposes users to a listed chemical above its “safe harbor” level. These thresholds—NSRL (No Significant Risk Level) for carcinogens and MADL (Maximum Allowable Dose Level) for reproductive toxins—determine compliance. If no safe harbor level exists for a chemical, businesses must evaluate exposure risks to decide if a warning is needed.

5. What Does a Prop 65 Warning Entail?

A Prop 65 warning must contain the word “WARNING” in bold and must be clear and reasonable, typically featuring language like:

WARNING: This product can expose you to [chemical name], which is known to the State of California to cause cancer and/or birth defects or other reproductive harm. For more information, visit www.P65Warnings.ca.gov.

These notices may appear on product labels, websites, or in-store signage to inform consumers effectively.

6. How Can I Ensure My Products Meet Prop 65 Standards?

For printers, your choice of substrate, inks, coatings and adhesives will affect your Prop 65 compliance. Speak to your suppliers about testing inks, coatings, and packaging materials for Prop 65-listed chemicals. Compare results to safe harbor limits (where applicable) and maintain thorough documentation. Partnering with a forward-thinking ink supplier like Zeller+Gmelin, who prioritizes formulation compliance, can streamline this process.

7. What Are the Consequences of Non-Compliance?

Failing to comply can lead to steep penalties—up to $2,500 per day, per violation. Costs can escalate quickly with multiple products or prolonged exposure. Enforcement comes from the California Attorney General, district attorneys, or private citizens acting in the public interest, making adherence critical.

8. How Does Zeller+Gmelin Support Compliance?

We understand the complexities of Prop 65 packaging requirements. Zeller+Gmelin is dedicated to developing inks, adhesives and coatings that meet regulatory standards without compromising performance. Whether you’re producing labels or packaging, our expertise ensures your materials align with Prop 65 requirements for printers. Have questions or need tailored solutions? We’re here to assist.

Your Partner in Prop 65 Compliance

Mastering Prop 65—from its chemical list to its warning protocols—doesn’t have to be daunting. Zeller+Gmelin is your trusted partner in navigating these regulations with confidence. Contact us today to learn how our compliant inks and coatings can support your business.

The post Prop 65 Frequently Asked Questions: Essential Insights for Print and Packaging Professionals first appeared on Zeller + Gmelin.

As a leader in UV ink solutions, Zeller+Gmelin has provided this guide to help you avoid common mistakes and adopt best practices for managing your printing ink inventory.

The Importance of Ink Inventory Management

Raw material mismanagement causes a host of pain points for industrial printing operations. As one of the highest cost consumables and a driving factor for print quality, ink management is especially important to maintain profitability and customer satisfaction.

Effective inventory management ensures high quality inks are available when needed, helping you avoid downtime and expedited shipping costs and improve material utilization. Plus, a reliable ink supply supports on-time order delivery and consistent print quality.

Common Pitfalls in Ink Management

Knowing the risks of inventory mismanagement is the first step, avoiding these common mistakes is the next. Zeller+Gmelin is a leading provider of printing inks for flexo, offset and commercial applications. With over 150 years in the business, here’s some of the common inventory mishaps we’ve seen that affect printers’ bottom lines.

Overstocking or Understocking: Excess inventory ties up capital and risks obsolescence, especially with UV/LED inks which have a shorter shelf life than others. While understocking can lead to production delays and expedited shipping costs, reducing your profit margins and productivity.

Inadequate Rotation: Failure to rotate your inventory and follow the FIFO (First In, First Out) method is a leading cause of ink expiration. Using expired ink may result in improper curing or adhesion and color inconsistency.

Improper Labeling: Mislabeling or lack of tracking, leads to confusion about ink age, type, or intended use. Poor label practices could increase the likelihood of accidental use of expired or incorrect inks as well as cause delays in production to find the right inks or resolve labeling issues.

Lack of Usage Monitoring: Not keeping accurate usage data can result in inaccurate forecasting and missed opportunities to optimize ink ordering. Profit margins dip when expedited shipping is needed to produce an order on time.

Poor Container Sealing or Storage: Open or improperly sealed containers can lead to contamination, drying, or curing of inks. Be aware of incorrect temperature, humidity, or exposure to light. These factors can degrade the ink over time or cause premature curing resulting in more ink waste.

Without a proper ink management system in place, these inventory mistakes can negatively impact your daily operations  and may be the culprit of low profit margins affecting your bottom line.

Z+G Inventory Tips for Success

Avoiding common inventory issues doesn’t require complex methods, you can start with simple improvements that make a big impact. These tips from our team of experts are actionable steps that you can take in your ink room.

Use an Inventory Management System: Implement software to track ink inventory levels, expiration dates, and usage trends. This can be as easy as a spreadsheet or software on a dispenser. More advanced tracking software can integrate with your production schedule and equipment, such as automated dispensers with built-in tracking sensors for ink usage monitoring in real time.

Adopt FIFO Practices: Standardize your ink receiving process to always rotate the oldest inventory to the front and place newer products behind, following the FIFO method to reduce waste. Confirm expiration dates when rotating to ensure the inks expiring first are easily accessible.

Standardize and Label Clearly: Label all containers with batch numbers, production dates, and expiration dates. Use color-coded systems for quick identification between ink types or applications. Using QR codes, barcodes or RFID tagging can make stock tracking more efficient and reduce manual errors. Periodically, inspect labels to make sure important information is not worn or torn off – relabel as needed.

Set Minimum and Maximum Thresholds: To maintain balance, define reorder points and maximum stock levels for each ink type. Use consumption data from your tracking system, set up automated alerts in your software, and take note of supplier lead times to optimize this component of ink management.

Dispose of Expired Inks Safely: Create standard operating procedures related to the disposal of each ink type used in your pressroom, to ensure environmental and employee safety. Incorrect disposal of expired inks can harm the environment and increase disposal costs, not to mention that failure to correctly manage hazardous materials can result in fines or legal issues.

Conduct Regular Training: Train staff on proper handling, storage, and inventory practices for UV/LED inks to minimize human error. Establish clear protocols for leaks, contamination and light exposure to effectively address potential storage issues and/or safety concerns. Standardize these ink management processes in written format and incorporate them into your onboarding programs for all applicable employees.

The Importance of Regular Audits

Conducting ink inventory audits at regular intervals is another way to prevent issues like overstocking, misidentified, and expired inks. We recommend creating a schedule or checklist to standardize the process.

 For larger operations with significant ink usage (over 20,000lbs/month), monthly audits ensure that your inventory remains manageable and optimized. Smaller printers with stable usage patterns can typically operate on a quarterly audit schedule to maintain order.

Spot audits are good practice when discrepancies are expected or after significant events like an ink room move or a new press install. Operations of all sizes should consider annual comprehensive reviews to reconcile inventory data with physical stock and to review supplier performance.

Ink Storage Best Practices

Protect your ink quality with this checklist for storage best practices.

Control the Environment: Maintain appropriate temperature and humidity based on ink type. UV inks require cool, dark storage, ideally between 60°F–77°F (15°C–25°C) to prevent premature curing.  Whereas, water-based inks need protection from freezing, which can break down their formulation and render the ink unusable. Humidity can cause some inks to thicken or separate, as well as increase the risk of microbial contamination in water-based inks.

Maintain Proper Seals: Use airtight lids and reseal containers completely and immediately after use to prevent contamination or curing. Inspect seals for wear and tear during your audits and replace any damaged lids or gaskets promptly.

Store Away from Direct Light and Heat: UV-sensitive inks and coatings can cure or degrade with exposure. Make sure UV/LED inks are stored in opaque containers and stored away from direct sunlight or artificial light.

Check Condition Regularly: Inspect containers for leaks, rust, or swelling, and take immediate action if found. Swelling of containers can indicate contamination or chemical reactions within the ink and should be addressed immediately. Log your inspections and analyze the data for recurring issues or trends in deterioration.

Segregate Storage: Store inks by type (UV, solvent-based, water-based) and label the areas clearly to avoid cross-contamination. Store inks used for specific applications, such as specialty or food-safe inks separate from your general use inks. Also be sure to create a clearly marked “waste inks” area for any products that need to be disposed of according to regulatory guidelines.

Proactive ink management will lead to smoother operations and ultimate cost savings for you, and better quality for your customers. Get started today with Zeller+Gmelin to avoid production delays, improve production efficiency, and maintain regulatory compliance.

Ready to optimize your ink room setup? Our team can help with auditing your current inventory and providing recommendations for improvement. Contact the Zeller+Gmelin team for ink and coating solutions, expertly done.

The post Ink Management – Setting up Your Ink Room for Success first appeared on Zeller + Gmelin.

De-Ink Rigid Plastics with EarthPrint Eco-Friendly Inks

Years ago, ink manufacturers were tasked with the challenge of formulating robust inks for rigid plastics that adhere incredibly and never wash off. Now, ink producers are being challenged with the exact opposite… READ MORE

Read EarthPrint Blog

The post Understanding Plastic Recycling Symbols (INFOGRAPHIC) first appeared on Zeller + Gmelin.

Infografía en español

De-Ink Rigid Plastics with EarthPrint Eco-Friendly Inks

Years ago, ink manufacturers were tasked with the challenge of formulating robust inks for rigid plastics that adhere incredibly and never wash off. Now, ink producers are being challenged with the exact opposite… READ MORE

Read EarthPrint Blog

The post Understanding EarthPrint Dry Offset Inks (INFOGRAPHIC) first appeared on Zeller + Gmelin.

As a global leader in printing inks and coatings, Zeller+Gmelin developed EarthPrint as a sustainable ink innovation for today’s eco-conscious printers. In this blog, we’ll discuss the ink and de-ink properties of EarthPrint dry offset inks and the impact they can make in sustainable rigid plastics printing and production.

Ink It Up

EarthPrint eco-friendly dry offset inks were formulated by Z+G for the utmost recyclability, while providing the same high quality color and adhesion properties Z+G inks are known for.

EarthPrint inks embody the enhanced chemical, water and scratch resistance properties of Zeller+Gmelin’s 71 series dry offset inks. Though capable of fully de-inking in a caustic soda wash, EarthPrint conversely adheres to rigid plastics with great strength and pigmentation. Boasting low odor and low misting properties, these dry offset inks remain stable at high press speeds with free radical chemistry and excellent curing capabilities.

So yes, EarthPrint inks are formulated to wash off, but don’t let the de-inking properties fool you. EarthPrint, like all Zeller+Gmelin inks, are developed for ultimate press performance, pigmentation, adhesion, curing and print quality. Now that we printed our cylinder with the utmost quality, let’s take a look at how to de-ink it down for ultimate recyclability.

De-Ink It Down

As raw material shortages and supply chain volatility continue, accessing virgin plastic material is becoming an expensive feat for many dry offset printers.

Though many rigid plastics are recyclable, the percentage of material eligible for recycling depends on how “clean” you can wash the printed plastic.

With EarthPrint, the ink formula gives way in the caustic soda wash, removing more pigment and leaving behind brighter, whiter recycled plastics. With higher amounts of ink wash off, the washed materials can be recycled into cleaner containers and tubes that require less virgin material.

Eco-Friendly All Around

Reduce. Re-use. Recycle. Thanks to EarthPrint inks, printers can reduce the amount of virgin materials used in recycled plastics, re-use more recycled materials in new products and recycle a higher amount of plastics than ever before.

Printers can contribute to sustainability throughout the full product lifecycle, by creating finished goods that can be recycled with brilliance, while requiring less raw materials.

Rest assured, our R&D Technicians strictly followed all Association of Plastic Recycling (APR) standards and protocols throughout the development and testing of EarthPrint to ensure ultimate container recyclability.

If you’re looking for new ways to increase your sustainability efforts in rigid plastics printing, EarthPrint is the solution for a sustainable future. Available in all PANTONE shades, EarthPrint can effectively replace your full dry offset ink inventory. Contact a Zeller+Gmelin Account Manager to discuss your print processes to see if EarthPrint dry offset inks are the best eco-friendly ink for your applications.

Understanding EarthPrint Inks Infographic

Browse through this educational infographic on EarthPrint inks to discover the features and benefits of the newest ink innovation from Zeller+Gmelin.

View EarthPrint Infographic

The post De-Ink Rigid Plastics with EarthPrint Eco-Friendly Inks first appeared on Zeller + Gmelin.