Utilization of Petroleum-Derived Waste Wax in Polyethylene Composites: A Sustainable Approach for Printing Ink Industry

The printing ink industry confronts considerable hurdles in balancing cost-effectiveness with sustainability, particularly when acquiring high-performance additives such as polyethylene wax. We offer a sustainable, cost-effective composite made from petroleum byproduct waste wax and high-Tg polymers (LDPE/HDPE), designed to replace traditional polyethylene wax. This composite solves both economic and environmental concerns by utilizing industrial waste while addressing the severe thermal, mechanical, and chemical requirements of ink formulations. The composite's uniform shape, crystallinity, and stability were confirmed through extensive thermal and structural characterisation using differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), X-ray diffraction (XRD), and scanning electron microscopy (SEM). The optimized formulation has a melting point of 88.5°C, hardness of 3 mm, and thermal stability up to 90°C, which roughly matches commercial benchmarks.When mixed into flexographic inks, the composite displays outstanding dispersion, near-comparable gloss (5% reduction), and abrasion resistance akin to normal waxes. Economic analysis shows a 34% reduction in material prices, demonstrating its industrial viability. This idea corresponds with UN Sustainable Development Goals (SDGs) 9 and 12, which promote circular economy concepts, by repurposing garbage into a high-value resource. The study not only provides a competitive alternative in the printing industry, but it also establishes a scalable framework for developing sustainable materials in industries that rely on high-performance wax composites. This strategy highlights the intersection of economic success and environmental responsibility, paving the way for greener manufacturing models.