In our first blog on circularity (Refurbish or replace? How dispensing valve remanufacturing reduces carbon footprint in packaging printing – GSE Dispensing), we discussed how refurbishment, upgrades, and reuse help extend ink dispensing equipment life.
During its lifecycle, ink changeovers often occur – due to supplier changes, new specifications, or compliance needs. While this may appear straightforward, the practical impact varies based on what’s changing and how the dispensing system is set up. This blog explores these considerations.
A common starting point: changing supplier, same ink type
One of the most common scenarios is a supplier change while keeping the same type of ink. A converter may continue with UV-curing, water-based or solvent-based inks, but source them from a new supplier, for example following the conclusion of a supply contract. In most cases the new ink behaves differently. Colour strength, viscosity, chemical composition and flow characteristics can vary, which may affect the outcome. These differences can generally be managed effectively by adjusting or reloading updated colour recipes and conducting a comprehensive calibration after the ink changeover Calibration and control of measuring devices – GSE Dispensing
The machine also needs preparation. Before the new ink is introduced, the system must be flushed thoroughly with a cleaning solution or transparent white (as recommended by your ink supplier) to ensure that pumps, hoses and valves are cleared of the previous ink. Since the swap stays within the same ink type, converters are typically able to perform much of this preparation in-house.
When UV change needs closer attention
Changing from standard UV to LED requires similar preparations as changing the ink supplier.
A more sensitive change is moving from standard UV ink to low migration inks Hazard analysis and risk management in packaging printing – GSE Dispensing. These inks use raw materials and chemistries with higher molecular weight that prevent migration. These ink ingredients may require the installation of special valves to ensure proper dispenser performance.
A much larger step is changing from water-based ink to UV ink. In many water-based systems, pumps and hoses are transparent, which is acceptable for water-based applications. With UV inks, however, light exposure can harden the ink inside the system. That means these components may need to be replaced with hardware suitable for UV use, such as pumps and hoses. Because of the scope of the changes, this type of conversion usually requires involvement of the equipment supplier and should be planned carefully, as it may result in machine downtime.
Knowing the technical limits
There are certain restrictions to consider. Moving from solvent-based ink to water-based ink is generally possible, since machines designed for solvents can also use water-based inks without issue. Learn more about switching from solvent to water-based ink dispensing in our blog, Automate your ink logistics for sustainable packaging!.
Modular dispensers, such as the Colorsat Compact, can be upgraded with up to 34 base components, enabling two different ink sets to be handled simultaneously. This feature makes it easy to transition from solvent to water-based inks while using up existing stock efficiently and minimizing waste.
The reverse is a different story. Changing from water-based to solvent-based ink is not feasible as a normal conversion, because solvent systems must be explosion-proof and properly grounded. In practice, that means the machine would need such extensive modifications that it is closer to a different machine than a simple upgrade.
Adapting your ink dispensing system for seamless changeovers
Switching ink or suppliers doesn’t mean a machine is obsolete. Many dispensers can be adapted for new production needs through cleaning, recipe adjustments, calibration or replacing parts.
| From current situation | To target situation | Impact | Measures | Involvement equipment supplier |
|---|---|---|---|---|
| Old ink supplier | Same ink type (WB, SB, UV), new supplier | Low | Flush system, adjust/ import recipes, system calibration | Limited |
| Solvent-based | Water-based | Low | Same as above | Limited |
| Standard UV | LED | Low | Same as above | Limited |
| Standard UV | Low migration UV | Medium | Same as above and possible valve replacement | Recommended |
| Water-based Standard UV | UV | High | Replace transparent hoses and pumps, clean valves, system calibration | Required |
| Water-based | Solvent-based | Very high | Major hardware changes required or machine replacement | Required |
In that sense, an ink changeover is not just a technical hurdle, it is also an opportunity to evaluate whether a system will remain reliable into the future. Rather than replacing a machine, converters may be able to extend its useful life by making the right technical modifications for the next stage of production.
Changing inks is possible in many situations, but it should not be treated as a routine product swap. With the right preparation and support, the transition can be managed in a controlled way.
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