blog over ALAR Unveils Flexostar System for Waterbased Ink Wastewater Treatment

Water-based inks bring vibrant colors and intricate designs to packaging, yet behind every successful print job lies a complex wastewater challenge. The mixture of inks, pigments, adhesives, metal ions, and fine solids creates a high-cost effluent that poses compliance risks. Implementing an autonomous treatment system like ALAR's Flex-O-Star® series enables effective control over discharges, significant cost reductions, and uninterrupted production efficiency.

In water-based printing processes, the resulting wastewater is far from simple rinse water. Even when labeled "non-toxic," concentrated ink residues in wash water and production discharges can overwhelm municipal treatment systems, creating compliance risks. This wastewater may also contain heavy metals (zinc, copper, lead, chromium), adhesives, starches, resins, and oils. Without proper treatment, these contaminants accumulate in pipes, damage infrastructure, and eventually enter the environment.

Pretreatment programs protect publicly owned treatment works (POTWs) by ensuring harmful pollutants are removed before discharge. A properly configured water-based ink wastewater system helps maintain metals, pH, fats/oils/grease (FOG), and total suspended solids (TSS) within permitted limits.

Outsourcing wastewater hauling proves costly and disruptive to production. On-site treatment significantly reduces disposal costs while giving operators complete control over discharge quality—resulting in less downtime, faster production cycles, and greater adaptability to changing requirements.

By treating wastewater before sewer discharge, companies prevent harmful contaminants from reaching local waterways—protecting aquatic life, preserving community resources, and demonstrating long-term commitment to sustainable operations. This approach also positions businesses as proactive contributors to public infrastructure protection.

ALAR's proprietary Flex-O-Star® system combines chemical pretreatment with mechanical dewatering to effectively remove inks and pigments at their source. The process includes:

• Chemical Conditioning: Adjusts pH, precipitates heavy metals, and separates adhesives, oils, and other contaminants.
• Mechanical Filtration: Uses Auto-Vac™ rotary vacuum precoat filters to capture solids down to one micron.
• Final Output: Produces clear effluent meeting discharge standards and dry solids suitable for landfill.

Each skid-mounted Flex-O-Star® system comes pre-piped and pre-wired for efficient installation. ALAR also provides consulting and pilot testing to ensure system configurations precisely match wastewater characteristics.

Water-based ink printing serves industries requiring high-precision applications across large volumes and diverse substrates:

• Corrugated Packaging: Boxes, cartons, and trays for shipping and retail
• Flexible Packaging: Pouches, bags, wraps, and laminates for food, cosmetics, and pharmaceuticals
• Labels: Pressure-sensitive, shrink, and multi-layer labels for bottles, containers, and consumer goods
• Paper Products: Envelopes, gift wrap, wallpaper, and commercial forms
• Plastic Films: Shopping bags, industrial liners, and packaging films
• Disposable Containers: Cups, plates, and foodservice items
• Promotional Materials: Scratch-off cards and specialty packaging
• Tapes: Printed tapes for branding or instructions
• Foil/Composite Materials: Specialty packaging and decorative applications

While composition varies by ink formulation and process, certain pollutants consistently require treatment:

• Pigments/Dyes: Persistent colorants requiring fine filtration
• Heavy Metals: Zinc, copper, lead, and chromium from ink formulations
• Adhesives: PVAs, starches, and binders causing sludge buildup
• Oils: Trace lubricants and ink components requiring separation
• TSS: Microscopic particles increasing pollutant loads

This self-cleaning rotary vacuum drum precoat filter produces sewer-compliant water and landfill-ready solids. The vacuum draws treated wastewater through a precoat medium that captures solids while an advancing blade scrapes accumulated material.

• One-micron filtration in single pass
• Eliminates clarifiers and sludge dryers
• pH-driven operation minimizes chemical use
• No filter press cycle delays
• Superior efficiency for ink solids, starches, and adhesives

This automated batch/continuous flow system combines chemical pretreatment with Auto-Vac® technology. The two-stage process includes chemical treatment (pH/ORP adjustment and polymer use) followed by mechanical filtration for solids removal.

This traditional liquid-solid separation system uses settling tanks for clear effluent production, with concentrated solids pumped to sludge tanks and filter presses. The Micro-Klean™ filter press features automatic hydraulic cylinders and solids collection bins.

ALAR serves multiple sectors requiring compliant discharge solutions for water-based ink operations:

• Ink, coating, and related product manufacturers
• Corrugated, carton, bag, and printing companies
• Plastic coloring and recycling industries
• Scratch-off card manufacturers
• Envelope and label producers

Each ALAR system is custom-designed to meet specific operational requirements while maintaining compliance with discharge regulations for metals, TSS, FOG, and pH.