In this study, a new waterborne acrylic copolymer resin (acrylic‐co‐resin) was synthesized to develop water‐based printing inks on polyester (PET) film. The synthesized acrylic resin showed good water solubility, high acid value (120 mg KOH/g), about 57% solid content. The developed water‐based inks (cyan, magenta, and yellow) exhibited small particle size (<1 μm) and optimum surface energy within required values (31.5, 32, and 30 mN/m) for good adhesion of ink upon PET films. The developed inks also showed good storage stability for 30 days. Further, to evaluate the application performance, the inks were printed on corona‐treated PET films at room temperature, and the ink drying time was measured. Further, the inks were printed on the corona‐treated PET film to evaluate the application performance. The developed inks showed a short drying time (7–9 s), which indicates their fast drying nature. Moreover, the developed inks showed good printability, color strength, high adhesion, and excellent rub‐resistant properties. Thus, the overall results demonstrated the potential of water‐based inks in printing applications.

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Rotogravure printing cylinders are engraved by electro-mechanical engraving (EME) process in India used for printing purpose. But this process has drawbacks of the emissions of hazardous gases, solid and water pollution. EME cylinders are better in cell size, depth and needed higher copper and chrome plating thickness. By laser engraving (LE) copper and chromium thickness were reduced by 75 µm and 5 µm in a cylinder by laser engraving with also a reduction in power consumption and plating time. The carbon footprints were also reduced by 227 g per cylinder with a cost-effective solution for rotogravure printing process.