BUILT-IN SUSTAINABILITY OF SAPPI DYE-SUBLIMATION PAPERS

Dye sublimation is a rapidly growing sector in the print market. The process is used in the printing of apparel, as well as soft signage, hard substrates (such as skis) and home decor.

A major part of the appeal of dye sublimation is its efficient use of resources and more eco-friendly methods. Over the past few years, Sappi has been upgrading its dye-sublimation paper production facilities, improving not just the product, but also its environmental performance.

Dye sublimation is a rapidly growing sector in the print market

Sustainability is a central pillar of Sappi’s business2. The company is committed to the United Nations Sustainable Development Goals (SDGs) – a blueprint for tackling climate change, poverty and inequality1. In Europe, this means a decrease of greenhouse-gas emissions from 2019–2025 of 25% and an increase in the share of renewable and clean energy by 11%. Sappi has also set the bold target of reducing carbon emissions by 41.5% per ton of product by 2030.

To these ends, Sappi Europe has implemented more than 80 projects. The projects prioritise exiting coal, increasing green electricity and investing in state-of-the-art technology and processes. All of this will improve efficiency and reduce emissions going forward.

As part of its decarbonisation objectives, Sappi has installed an e-boiler at its Maastricht Mill in The Netherlands. As a result, the mill’s CO2 emissions are reducing, while at the same time contributing to the stability of the wider electricity grid. At Kirkniemi in Finland, the facility has switched to bio-energy. This has resulted in a saving equivalent to 230,000 tons of CO2 emissions annually. At Sappi’s Gratkorn Mill in Austria, a state-of-the-art heat pump has been installed. The pump not only cuts CO2 but also excess heat for use in the nearby city of Graz.

In addition, as part of these company-wide efforts, Sappi recently revamped its Transjet dye-sublimation paper production at its Carmignano mill in Italy. This has increased capacity and brought into operation a new finishing area consisting of two new plotter-converting machines and an automated packaging line. Customers now receive faster, more responsive order fulfilment. Additionally, the upgrade to the in-house packaging and storage, reduces the carbon footprint of each order. The business has also switched to mono-material packaging for its papers in order to improve recyclability. 

These improvements build on the inherent environmental advantages of the dye-sublimation process when compared to direct printing.

Sustainability is a central pillar of Sappi’s business

The dye-sublimation process begins by printing a design onto special transfer paper using sublimation inks. This paper is then placed onto the synthetic fabric or material of choice. Heat and pressure are then applied in the transfer press or calender. In this way, the design is permanently bonded to the textile fibres or the polyester mass. As the material cools, the dye links to the fibres or substrates, resulting in a durable, full-colour print that is resistant to fading and washing.

As this process is essentially a dry-heat transfer, it does not require any water. In addition, there is no requirement for any pre-treatment or post-print washing steps which are necessary in direct printing. There is also little waste – all of Sappi’s Transjet and Basejet ranges of dye-sublimation papers can be recycled. Sublimation papers are available on request as FSC Mix Credit (FSCTM-C015022) or 100% PEFC (PEFC/07-32-76) certified. Ultimately, the dye-sublimation process saves materials and production time which, in turn, saves energy. The process also uses solvent-free, water-based inks. 

As part of the extensive technical support provided, Sappi’s experienced engineers offer expert colour-management advice and assistance. This allows for optimisation of the entire production process, from start to finish.

Customers are drawn to dye sublimation in part because of the comparatively low cost of entry in buying a printer and heat press. It also means affordable ongoing costs in ink, paper and consumables. It is a relatively easy process to learn and is easy to scale incrementally by adding new printers as demand grows

The adaptability and cost-effectiveness of the technology supports re-shoring. In other words, printing operations are set up near knitting and sewing sites closer to the end consumer. Benefits include fast order turnaround within the fashion industry’s frequent collection changes, reduced transport and delivery related costs, and the social benefits that come with job creation in local communities.

Sappi’s investment in dye-sublimation printing is just part of the company’s ongoing efforts to improve efficiency for customers and bolster environmental stewardship. Such initiatives are one of many steps Sappi Europe is taking on its path to realise sustainability goals and meet ambitious decarbonisation targets for 2025 and beyond.

1. Smithers The Future of Digital Textile Printing to 2028
2. Sappi Sustainability targets – www.sappi.com/our-sustainability-targets-for-a-thriving-world