How Apex and Coveris Reduced CO₂ Emissions While Improving Print Performance
Sustainability has become a top priority across the packaging industry. Brand owners, converters, and printers are under increasing pressure to reduce environmental impact while maintaining productivity and profitability.
The challenge is that many sustainability initiatives are often viewed as a tradeoff between environmental responsibility and operational performance.
A multi-year collaboration between Apex International and Coveris Flexible Packaging has proven otherwise.
Through the implementation of Apex's GTT® anilox technology, Coveris successfully reduced ink consumption, lowered CO₂ emissions, and improved operational efficiency without compromising print quality or production performance.
A Long-Term Commitment to Measurable Results
The project began in 2020 and continued over a five-year period to ensure the collection of robust production data and repeatable results. The goal was simple:
- Reduce ink consumption
- Lower environmental impact
- Maintain premium print quality
- Improve production efficiency
The results exceeded expectations.
18-20% Reduction in Ink Consumption
Testing demonstrated reductions of between 18% and 20% in the amount of ink used due to the advanced design of the GTT engraving.
By improving ink transfer efficiency and delivering a more consistent ink laydown, GTT technology 
enabled the same high-quality print results while using significantly less ink.
Less ink usage means:
- Lower material consumption
- Lower operating costs
- Reduced environmental impact
- Improved process efficiency
More Than 26 Tonnes of CO₂ Savings Per Press, Per Year
Perhaps the most impressive outcome of the project was the measurable reduction in carbon emissions.
Testing demonstrated annual CO₂ savings exceeding 26 tonnes per press through reduced ink consumption alone. In an industry increasingly focused on sustainability reporting and ESG initiatives, reducing emissions at this scale can have a meaningful impact on both environmental goals and corporate sustainability programs.
Up to 20% Energy Savings
The benefits extended beyond ink reduction.
Because less ink was being applied, less energy was required during the drying process, resulting in additional energy savings of approximately 20%.
This creates additional cost savings while further reducing the environmental footprint of the printing operation.
Improved Productivity and Reduced Maintenance
The project also demonstrated several operational benefits, including:
Shorter cleaning cycles- Longer doctor blade life
- Reduced maintenance requirements
- Increased press availability
- Improved productivity
Testing showed that the GTT structure contributed to longer service life for doctor blades and improved machine efficiency.
The result is a more efficient and more sustainable printing process.
Sustainability and Cost Reduction Can Go Hand in Hand
As Christian Huth, OEM Manager at Apex International, explained: "Achieving sustainability goals and cost reduction are not mutually exclusive."
This project demonstrates that sustainability initiatives can deliver measurable financial benefits while helping companies reduce their environmental impact.
Download the Full Case Study
Want to learn more about the testing methodology and complete results from the Apex and Coveris collaboration?
Download the complete Sustainability Case Study to discover how GTT® technology can help your operation:
✅ Reduce ink consumption
✅ Lower CO₂ emissions
✅ Improve energy efficiency
✅ Increase productivity
✅ Support your sustainability and ESG goals
