Product, Feature or Process Owner/s



Green LongLife™ is the updated sustainable pre-coating solution that is optimized in all aspects of sustainability, especially a low product carbon footprint (PCF) in production and the avoidance of plastic and microplastic materials leading to a high biobased carbon content (BCC). Its predecessor, the durable, pre-print coated banknote substrate LongLife™ is already successfully in circulation in high-volume countries such as Thailand, Philippines and Turkey achieving a significantly longer life span and cleaner banknotes in circulation.

The aim of the project was to anchor these two objectives in the new solution and enable a seamless transition for central banks in their cash cycles and printworks in their banknote manufacturing process.

All key aspects of the cash cycle were considered: Production, the printing process and disposing of worn banknotes in the most environmentally friendly way possible. With Green LongLife™, we have succeeded in launching a solution that performs perfectly in all these disciplines without having to change existing machinery and processes.

In addition to its sustainability and durability properties, Green LongLife™ can also host a dynamic range of security features. To demonstrate this in the House Note version, RollingStar® LEAD Mix supports optimized storytelling and counterfeit resilience by harmonized integration of the print, to the animated structures featuring micro mirror technology, modern holography, and attractive color shift effects. The Galaxy® security thread, with sophisticated micro mirrors, delivers faster dynamics, stunning color shifts, and beautiful flip effects.

Improvement of the Banknote or Printing Process

The innovative Green LongLife™ pre-coating, which is based on renewable materials, achieves the same high level of soil repellency as conventional pre-coating technology. The various options for certified, sustainable cotton such as organic cotton and Cotton made in Africa (CmiA) can be used. Recycled materials can be used for the security threads and foils. Furthermore, mineral-oil free simultan printing inks are compatible with the substrate and the general printing performance is unaffected.

Innovation and Unique aspects

Green LongLife™ combines a full range of innovative developments that make it a unique sustainable substrate solution:
• 100% certified organic cotton
• Louisenthal is certified for the Cotton made in Africa (CmiA) supply chain and can therefore offer CmiA-certified cotton as an alternative sustainable option
• Binder for pre-coating made from renewable raw materials (sugar cane)
• carrier foil for the Galaxy® security threads and RollingStar® LEAD foils made from recycled polyester (70% rPET)
• mineral oil-free printing inks for simultan printing are compatible and were used on the House Note
• plastic-free, multicolored cellulose-based fluorescent fibers to avoid microplastics
• compatible with post-print UV varnish such as TOPnote® to further extend the lifespan and further increase soil repellency
• 100% green electricity for papermaking, security feature production and banknote printing
• multiple repurposing options from thermal recovery and composting to the innovative banknote fiber extraction
• remarkably high biobased carbon content of over 90%
• low product carbon footprint due to the above measures leading to a reduction of 30% compared to conventional LongLife banknote

Environmental Impact

In combination with the aforementioned measures, a significant 30% reduction of the Product Carbon Footprint (PCF) is achieved compared to the standard. The adjustments were made while maintaining the excellent circulation performance of the existing and well-proven LongLife™ substrate. A lifespan up to 2 times longer compared to standard cotton multiplies the CO2 savings due to less demand for banknote replacements.

In addition, an independent certification (DIN Certco) has confirmed a very high biobased carbon content of 91% and the highest possible category of bio-based products. Green LongLife™ is therefore currently the best possible durable substrate solution to be composted at the end of its life cycle. Other repurposing options such as the novel Banknote Fiber Extraction process or thermal recycling work also very well.



Categories: Technical Awards 2024
Tags: Best New Banknote Feature Product or Process