Sustainability: label converter production performance

These implementations, combined with numerous others on the exterior of the building, allowed the architect to reduce the size of the mechanical system, thereby further reducing energy consumption (the bigger the system, the higher the consumption).

Specific design elements were implemented to reflect the connection between the building and product and packaging development. For example, the concrete floors are made up of recycled content stripped from consumer product waste such as plastic bottles. The project has received an innovation credit for having over 30 percent recycled content within the building, including the furniture. Even on-site benches and mulch were harvested from trees on the plot of land. Water is recycled through a bio-swell.

The building received another innovation credit because more than 30 percent of the supplies used were regional materials. The majority of the project’s materials are made in South Carolina – including the bricks, concrete and steel. This, combined with locally contracted business, significantly reduced the CO2 emissions during the project’s completion.

Since 2009, the Green Building Certification Institute (GBCI), which includes a network of ISO-compliant international certifying bodies, has been the independent, third-party auditor, established in 2008, to administer LEED project certifications. The GBCI oversees the certification process of all international LEED projects to give multinational businesses the ability to embrace ‘green’ building across an entire portfolio. It accounts for regional differences to provide global consistency and to provide the ability to benchmark across borders.

The Rating Systems with international options became available at the beginning of 2011. It is supported by the LEED International Roundtable that consists of representatives from national ‘green’ building councils and organizations around the world. Wisconsin-based converter Lauterbach Group and Toronto-headquartered converter Metro Label have achieved LEED certification at some of their facilities.

Lauderbach Group comments on its LEED sustainable building certification: ‘The old adage that it costs more to do this stuff is more of a fallacy. The investments that we made in the building were quick paybacks.’

In early 2011, P&G pledged to pursue LEED sustainable building certification for all of its new sites globally. Its Taicang, China, plant will be the first of its manufacturing sites to pursue LEED certification.

Note that acute studies on LEED certified building energy consumption have revealed that while LEED buildings consume as much as 35 percent less energy per square area when compared to traditional constructions, as many as one third of certified buildings consume more energy than conventional buildings.

BREEAM – UK - The UK’s BRE (Building Research Establishment) established the BREEAM (BRE Environmental Assessment Method) scheme in 1990 and has since certified over 10,000 buildings worldwide. BREAAM also offers global opportunity, with structures that include Europe and BREEAM Gulf. All address the specifications inherent to each nation or region.

Since 2008, a number of European countries have validated the BREEAM International framework through their official bodies. Among them is the Netherlands, validated by the Dutch Green Building Council, which launched its locally adapted version of BREEAM NL in October 2009. Ireland, Spain, Latvia, Turkey, Norway, Sweden, Russia, Poland and Bulgaria have partnered with the rating system and are in the process of adapting it through their respective national Green Building Councils and building stakeholder leaders.

The partnership objectives are to develop versions of the program available in the local language and managed locally to ensure national ownership within the overall international framework. The development of the Common Carbon Metric opened the door for BREEAM to work in partnership with the rating tools operated by Green Building Councils, creating a global reach to truly reduce any building’s impact on the environment.

Green Globes - In 1996, the Canadian Standards Association (CSA) published ‘BREEAM Canada for Existing Buildings’. In 2000 the scheme transformed into an online assessment and rating tool under the name Green Globes for Existing Buildings, and quickly developed an Existing Buildings program with federal support. The Building Owners and Managers Association of Canada (BOMA) adopted Green Globes for Existing Buildings in 2004 and acquired rights to distribute in the US. Green Globes is accredited by the American National Standards Institute (ANSI).

CSTB – France - In June 2009 France’s CSTB (Centre Scientifique et Technique du Bâtiment) and its subsidiary CertiVéA signed a memorandum of understanding to work with the global arm of BREEAM to develop a pan-European building environmental assessment program. The program is similar to the French HQE (Haute Qualite Environmentale), which is the standard for ‘green’ building in the country; however, there has not been much progression of the project since the agreement

Green Star – Australia - Australia’s Green Star environmental rating system for buildings was launched in 2003 by the Green Building Council of Australia (GBCA). The GBCA has played a prominent role in the WorldGBC. In 2006, the GBCA worked collaboratively to support the establishment of the Green Building Council of New Zealand and more recently the Green Building Council of South Africa. Both councils have adopted the Green Star rating tool and modified it for the unique conditions of their own countries.

WATER RECOVERY SYSTEMS

Water usage is an important part of a building’s overall efficiency. Active water conservation can save building consumption and demand charges.

The investment cost is comparatively low and the return on investment quick when proper evaluation is applied.

Making simple changes around the building to faucets, toilets and urinals to low flow systems can show a significant reduction in water usage. Graywater is waste water from showers, sinks, washing machines and tubs.

Depending on local regulations, two separate recovery systems – graywater and blackwater – can be used and treated appropriately. Graywater can be more simply recovered and reused in toilets, irrigation systems, chillers and for other non-potable water uses.

Graywater is distinct from blackwater, which comes from sources that contain toxic or organic matter like food. Blackwater, which is produced in many label and packaging production plants, can be recovered, treated properly and dispelled into the system in accordance with local regulations for reuse. Water recovery systems reduce manufacturing strains on local water resources and ensure that contaminated water is not sent into the surrounding water table.

Paragon Label only uses water-based inks and, according to current environmental regulations, these inks can be washed down the drain. Still, the company actively chooses to reduce its strain on the California sewer system and to further reduce its environmental impact. The converter says that with the recovery system, water discharged from the facility is cleaner than the water coming in.

Rainwater recovery is another way to conserve water in and around a manufacturing plant. There are simple and complex systems that can be designed for a new building structure, or that can be retrofitted to work on an existing building.

In order to capture rain water for storage and reuse, there needs to be a designated area to recover water, known as the catchment area. This can be as easy as a barrel under a spout, a flat top roof, a parking lot or a patio. Most importantly, the material used to collect the water – concrete, metal, etc – should not contaminate it upon collection. Once a collection location is established, an infrastructure must be created to lead the water to a storing point where it can be cleaned, if necessary, and saved until use in specific areas within the building, or externally for irrigation.

CASE STUDY – WATER RECOVERY

Clemson University’s Sonoco Institute for Packaging Research captures water to be recycled through what is called a ‘bio-swell’. This captures the majority of the water on site and filters it before it returns to the water supply. This feature, along with various other water flow reduction systems within the building, gave it a minimum of a 40 percent reduction in water usage. A LEED innovation credit was awarded as a result.

ENERGY CONSERVATION IN THE LABEL PLANT

Eighty-two percent of all greenhouse gas emitted by human activity, which includes walking, driving a vehicle and manufacturing, is energy-related carbon dioxide. Manufacturing makes up about 80 percent of industrial energy consumption, which also accounts for an estimated 80 percent of industrial energy-related carbon emissions. The global energy demand is forecast to grow by 57 percent in the next 25 years and around 30 percent in the US and Europe.

MODERATE ENERGY USAGE

Lowering a facility’s peak demand is a key step to improving load factor and will reduce the amount paid per kWh for electricity for customers on a demand rate structure. Look at how and when you use electricity to find ways to control your load factor. Install higher efficiency lighting or air conditioning. Scheduling or staggering large electric loads so they don’t start simultaneously may also help. It is important that energy consumption is addressed during unoccupied hours as well as operational periods.

The most important preparation step is to create a formal energy policy with a commitment to continuous improvement. Industry leaders must realize that a formalized energy consumption policy can fight inflation problems, provide global economic independence, enhance competitive advantage, save money and energy, reduce greenhouse gas emissions, alleviate business demand on the grid and meet the Sustainability Scorecard requirements of brand owners and retailers as described.

CREATING AN ENERGY POLICY

An Environmental (Energy) Management System (EEMS) will generally include some or all of the following elements, and is similar to a standard EMS;

• The writing of an energy policy statement

• Setting out the organizational management structure to implement the energy policy

• Providing information about personnel and job responsibilities

• Setting out what the energy review and energy planning process will contain

• Developing guidelines on the practices, procedures and processes to be used

• Providing information on the resources being made available for developing, implementing, checking and achieving the EEMS

• Establishing procedures for reviewing, maintaining and improving the environmental (energy) management system and policy, plus management reporting

An example of an environmental energy efficiency policy is shown at the end of this articles. 

IMPLEMENTING AN ENERGY POLICY

There are a number of important steps to be undertaken in implementing a label converter energy policy. These can be seen in Fig 4.6.

Rising awareness of the strain on the globe’s electrical grids, the depletion of energy fuel sources, rising costs and rapidly increasing demand has the world scrambling to create solutions to these problems.

With the incorporation of digital technology into an electric grid system, a smart grid that allows for two-way communication between the utilities company and the consumer is gaining popularity. Unlike the current single directional grid system, a smart grid can monitor and control appliances within the home or business, assisting utilities companies in meeting the demands of the population, while at the same time empowering the general consumer and business leaders to control their individual effect on the grid and reduce their home or business’ carbon footprint.

Private funding and US legislation such as the Energy Policy Act of 2005 and Title XIII of the Energy Independence and Security Act of 2007 promoted the idea of a smart grid, but has not gained much traction in the wake of the global 2009 recession. As set in 2010, the European Council is not on track to meet its 20 percent energy efficiency target for 2020; however, in a meeting held on February 4, 2011, legislative action was called to assist in meeting this goal and to speed up the construction of an interconnected and fully integrated internal energy market for the region.

Typically, energy is stored in large amounts on the grid, saving excess production at times of low demand for when production cannot meet consumption. This allows the entire process of energy production and distribution to remain relatively constant. Energy grids that are connected to intermittent resources like wind and solar can realize significant cost benefits by depending on these renewables to support consistent supply with the rise and fall of demand.

Intermittent resources are those that are not continuously available and capable of being dispatched to meet demands of a power system. These sources are most often used to displace the fossil fuel required for most common energy production – coal, nuclear, geothermal, solar thermal and biomass.

RENEWABLE ENERGY/ALTERNATIVE ENERGY

Renewable energy, or alternative energy, is naturally sourced and replaced seamlessly, such as the sun’s light, wind, rain, tides and geothermal heat. In 2008, about 19 percent of global final energy consumption came from renewable sources.

Global renewable energy capacity advanced in 2009, when both the US and Europe, for the second consecutive year, increased power from renewable sources more than conventional sources like coal, gas and nuclear. UNEP reported that 60 percent of newly installed capacity in Europe and 50 percent in the US was from alternative options.

In 2009 renewable sources represented 25 percent of global power capacity (1,230 gigawatts (GW) of 4,800 GW total) and 18 percent of global power production. Wind power has consistently grown 30 percent annually around the world for some years. Global investment in wind power grew from $59b or 45 8%.

Most of the industry’s leading ink suppliers are taking sustainability seriously in a variety of ways. Some have established sustainability reports that provide details about what the company is doing internally, providing more transparency for converters through the supply chain. Others are working with third-party auditing firms to validate their sustainability programs and certify various products to environmental credibility. They are introducing new inks and researching and developing the advancement of renewable content products.

Sun Chemical is in its third year of sustainability accounting and is constantly investigating how it can lower its total carbon footprint. It has developed SunCare in cooperation with EnviroN, a third-party support line specializing in sustainability, to provide environmental consultative assistance to its customers. The ink supplier also provides product life cycle data, currently reporting only on its gate-to-customer-gate data. Taking its analyzes a step further, it will soon begin to evaluate its own supply chain.

BASF eco-efficiency analysis - Chemical company BASF, a producer of ink resins, in 2008 compiled an eco-efficiency analysis for flexographic inks in film applications. An eco-efficiency analysis compares both the economic and environmental impacts that a product or process has over the course of its life cycle.

The study compared water-based, solvent and UV printing inks with 25 percent image coverage on 0.003mil film. Each product was weighted in six environmental categories – land use, energy consumption, emissions, toxicity potential, risk potential, resource consumption – against cost. In the end, the research concluded that water-based inks are the most environmentally friendly, lower-cost choice of the three flexographic inks.

The BASF study was completed on a CI press in the midwestern United States. The study found that solvent-based ink consumed the most energy throughout the entire cycle, mostly due to the chemistry involved in the ink formulation. Solvent-based inks were also found to use the highest amount of natural resources while water-based and UV inks consume relatively the same.

When looking closely at emissions or the possible Global Warming Potential (GWP), UV-curable inks were found to have the most negative impact because of electricity usage, which is more inefficient than gas.

ECO-INKS

Using inks which have all heavy metals eliminated from their formulas and which contain only trace amounts of VOCs is a step to becoming more environmentally friendly. Many alternatives to solvent-, water- and UV-based inks have recently hit the market, including soy and corn-based products and percentage renewable content, which effectively reduce emissions without compromising quality.

The National Association of Printing Ink Manufacturers offers a verifiable certification of the Bio-derived Renewable material Content (BRC) of ink.

BRC is dependent on the printing process and application due to the physical/chemical requirements of the printing press and the means used to dry the printed ink film. Therefore, BRC values cannot be compared between different ink types. Each ink type has its own range of potential BRC.

Vegetable-based ink serves as an appropriate replacement of traditional petroleum-based ink for lithographic and letterpress printing. The US Department of Printing uses only ink with a non-toxic vegetable oil base, which contains a combination of soy, cottonseed, corn and other vegetable oils. The ink virtually eliminates toxic air emissions and hazardous waste, improves indoor air quality and qualifies as a renewable resource.

The Flint Group offers BioCure F UV curable flexographic inks made up of 10 percent renewable linseed oil acrylate in replace of traditional resin. It also has a water-based AquaSoy line with a resin made of soybeans farmed specifically for alternative sources. The American Soybean Association has created the Soy Seal which verifies that water-based flexographic inks have at least 15 percent of the resin from soybean oil.

Zeller+Gmelin too offers its Nuvaflex 35 Series of 20 percent renewable content UV flexographic inks, including an opaque white. The company claims that the inks release less than one percent VOCs when polymerized.

Nazdar has a water-based line of caustic soluble inks for reusable bottles, much favored by the Latin America beer market and other beverage sectors in the region. This soluble ink washes out in caustic solution without harming the integrity of the paper label waste stream, a very important aspect when reviewing a product’s life cycle impact

INX has certified a line of its sheet-fed inks to EcoLogo, an environmental standard and certification mark established in 1988 by the Canadian government, but is now used globally. EcoLogo meets the ISO 14024 standards for eco-labeling.

WATER-BASED AND UV

Aqueous, or water-based, coatings are used to protect printed items from damage such as scratches and fingerprints. Unlike traditional petroleum-based coatings, aqueous coatings do not produce any hazardous emissions and are considered non-toxic.

Water-based inks should be used wherever possible – flexography, gravure, offset and screen printing. While some printers claim quality faults with using water-based inks, many report vivid color produced on a variety of materials, more consistent viscosity throughout a print run and better coverage, which reduces the amount consumed and therefore reduces costs.

There are a number of reliable suppliers, international and regional, that provide dependable water-based inks. For example, Actega WIT offers a water-based bright metallic ink designed to have extended shelf and press stability as well as advanced trapping capabilities. It also has water-based gloss and matte finish varnishes for the wine label market.

The difficulty with using water-based inks is the required drying time. UV inks are cured with the use of a UV light, curing a mostly solid ink film and almost eliminating the release of VOCs from the ink content into the air. However, they require the use of acrylate resins, which are irritants. UV radiation can be damaging to the skin, produce ozone from atmospheric oxygen and consume reasonable amounts of energy.

INK CONTAINER RECYCLING

A number of label and packaging converters, with the support of their ink suppliers, are reducing, reusing and recycling inks and the containers they are delivered in. INX offers customers ‘A Basic Guide: Customer Waste Management Options’ as a tool to reduce their waste and carbon footprint for this production aspect.

The guide informs customers of the recyclability of its plastic ink containers and the various outlets available, including commercial and industrial recycling programs and waste to energy by incineration. It explains that national and regional facilities will collect the containers, but that each may have different standards for cleanliness, scraped versus triple rinsing, so it is important to check with local firms for specific criteria. The INX guide provides a basic grid for converters to evaluate which recycling stream will work best for their operations.

ENERGY REDUCTION IN UV AND DRYING SYSTEMS

UV curing refers to the way in which coatings, inks and adhesives are dried using energy from UV light radiation sources rather than conventional heat. The traditional UV lamp curing system consists of lampheads, reflectors, cooling systems and an electrical/electronic source.

The most common type of UV lamp is mercury vapor because it offers the broadest arc spectrum. There are also metal halide doped lamps where the mercury is mixed with iron or gallium to modify the spectrum range. Typically it is recommended to use a mercury vapor lamp for any possible curing application because it has more longevity than halide versions and typically less expensive.

Sophisticated electrical systems are used to ignite, warm up and operate high intensity, medium-pressure mercury vapor lamps. Each lamp requires high voltage to initiate the arc and a lower voltage to maintain it during operation.

To ensure constant curing speeds, the electrical system is power-regulated by a three-phase voltage stabilizer or ballast. A stabilized system supplies constant power to the lamp even with variations in the line voltage. Infinitely variable output power provides finite control and efficient running of UV lamps.

In most cases, one ballast is required to operate one mercury lamp. Each ballast supplies constant power to the lamp. Lamp power variation will not exceed + 3 percent with line voltage fluctuations of up to + 10 percent. As supplied, the ballasts will operate the lamps at full power. However, operation at 75 percent or 50 percent output is possible by use of a capacitor-switching network. Switched-capacitor networks allow for electronically variable resistors, with no moving parts, which makes the voltage input adjustable as compared to standard resistors. Ballasts are available in a variety of input voltages and for operation on either 50 or 60 Hz.

The output voltage from a transformer/choke ballast type supply is approximately sinusoidal at 50-60Hz. The lamp UV output is dependent on the magnitude of the input voltage, hence it is pulsed at double the input voltage frequency. Three-phase input, balanced under all load conditions and stabilized constant UV output during main voltage fluctuations (within 370-480V, 50-60Hz).

A rectangular current output causes an approximately 10 percent greater UV yield for the same electrical power compared to the sinusoidal power output of a conventional transformer/choke ballast. Typical lamp output varies at 100-120Hz.

Low power and high power systems can cure many label applications with 140W/cm, yet many of the more complicated unsupported film applications will require curing at 200W/cm to the substrate.

GEW was the winner of the first annual Global Green Award at Labelexpo Europe 2009. All supplier submissions for the award are cross-evaluated using five factors: pollution reduction/prevention, environmental leadership and economic effectiveness as well as relevance to the industry, responsible sourcing and potential for advancement.

GEW was selected for its e-System UV ink curing equipment. Its e-System, e-Brick lamp control and power supply boost UV output by 20 percent by incorporating high-voltage, high-frequency square-wave technology. This control also gives more overall curing consistency. At the same time, it reduces running power for a comparable curing system by 30 percent. The system decreases CO2 emissions by 30 percent while extending lamp life, bringing significant cost savings to users. The e-System can be incorporated into any press type and has multiple installations around the world.

Compared with conventional UV curing technologies, the e-System range of electronic power supplies and optically perfected lampheads has had the potential to have collectively saved customers an estimated 35.700 tonnes of carbon dioxide emissions and 8.6 million euros when compared to conventional transformer/choke ballast supplied UV curing systems.

The e-Brick is compact, lightweight and stackable, with less than 30 percent of the volume and 20 percent of the weight of conventional systems, reducing shipping size, weight and cost. The output voltage from an e-Brick is square wave at 300Hz.

UV lamps emit heat during use, so a cooling component is required. UV lamps can be cooled by air extraction or water-cooled. It is important to ask suppliers which cooling system works most effectively for the products produced on press. In many cases air extraction systems can incur higher costs as opposed to water.

UV output automation - GEW introduced an automatic control system for the UV output level of its e-Brick systems to work in direct proportion to the press speed. With the use of an integrated control program, diagnostic features are monitored to optimize UV output, enhance lamp longevity and the UV curing system’s overall performance. With the automated system, the company aims to help its customers further reduce energy costs and prevent spoiled print jobs by using the minimum power required to cure, with extra in reserve for the more difficult jobs.

Using the system, GEW customers can select the power level required for the job depending on the properties of the ink, coating or adhesive at the appropriate press speed. Rather than being manufacturer-set, users are now able to select whatever power they need to print a specific job, while being assured of the highest level of energy efficiency.

UV systems are frequently left on stand-by between runs, shift changes and break periods, so they are ready for operation when the operator wants to start producing an order. An intelligent GreenTimer automatically switches the system on and off, documenting peak and low period usage so cost savings can be easily quantified.

Whether lamps are cooled by compressed air or water systems, maintenance and cleaning should be scheduled on a weekly or bi-weekly basis depending on press and system usage.

LED CURING

UV LED curing technology, which is mercury-free, does not generate ozone harming emissions and new developments are allowing for accelerated production speeds, lower production costs and reduced energy usage compared to traditional lamps. While it is rising as an option for alternative curing, many inks formulated for the industry have not been developed to optimize cure with this technology.

Phoseon’s ELC line of electronic power supply units operates with low energy input. The UV unit can be operated in stand-by mode with lamp output of 20-30 percent. The system is equipped with output control for consistency and accurate temperature control. An integrated control and monitoring system allows the unit to operate consistently under network voltage variations of ±10 percent.

LED curing can perform cure of inks and coatings on heat-sensitive substrates without distortion. The lamp can be switched to energy-saving stand-by mode and the lamp output can be automatically adjusted between 25-100 percent depending on the print speed. The ELC range lamp outputs from 4kW to 32kW.

Phoseon’s patented Semiconductor Light Matrix technology uses high power UV LED technology with semiconductor arrays that can be turned on and off during the manufacturing process. The LEDs do not produce excess heat and can be disposed of as regular waste, whereas UV lamps with mercury become hazardous materials at the end of their life cycle.

Note that all modern UV curing systems are able to automatically switch into stand-by mode when the press is not in production where the power level is between 18-50 percent of full power.

Mark Andy and Flint Group have championed LED-UV for flexo presses, while digital applications typically include inter-color pinning. EFI Jetrion launched an inkjet press using LED-UV for final cure at Labelexpo Americas 2014.

SUSTAINABLE PRESS ENGINEERING

Label press manufacturers have done a considerable amount of work in recent years to make label printing equipment more sustainable, to reduce set-up and running time, to reduce press running waste and to re-engineer press technology taking into account life cycle considerations.

Gallus, for example, has reviewed the environmental conditions of label printing machinery and press rooms, assessing environmental interfaces and looking at where waste reduction, energy efficiency, noise and heat occur in the press environment.

These areas can be seen in Fig 4.16.

Taken further, this has enabled Gallus to look at areas of energy consumption on a label printing press (see Fig. 4.1) and then work on each of these areas to convert sustainability into an economic benefit in the press design. As can be seen in the diagram, UV drying has traditionally been a large area of energy consumption on a label press. Now, with the Gallus ECS 340 UV-curing system without exhaust and the newest reflector and lamp technology, energy costs have been reduced by up to 10,000 euros per annum, ozone discharge into the environment has been eliminated and, thanks to centralized water cooling of the machine and UV-curing system, a temperature potential of two to three single-family homes is accessible for a heat exchanger solution.

In terms of press design, the Gallus RCS 340, for example, has been designed with a short web path, which is claimed to reduce the total web in the machine from approximately 50 meters down to 12 meters. This in turn is said to reduce production waste by around 10 tonnes per annum, and a cost saving of 40,000 euros per annum.

Functional press design can both help to reduce energy costs for manufacturing and significantly shorten press manufacturing lead time. Historically, says Gallus, a printing unit would be built out of some 300 parts; today, the newest generation consists of just 90 parts.

While these examples of more sustainable press design have been taken from examples given by Gallus, most leading label press manufacturers will be working towards similar or alternatives approaches to press sustainability, energy efficiency and waste reduction in their latest generation of presses.

Label converters utilizing these latest designs of label presses, and implementing other label manufacturing efficiencies such as automatic inspection, sophisticated ink dispensing systems, new cutting technology and a commitment to recycling, can today achieve significant cost savings. This can be seen in the following case study.

WHOLE-BUILDING ENERGY CALCULATION

Many methods and tools are available to perform an energy analysis in order to create a baseline for a label and packaging converter’s energy policy. There are a number of computer simulation software programs available for both new building design and for established manufacturing sites, as well as various online energy calculators that focus on specific regions and energy sources.

The US Department of Energy, Energy Efficiency and Renewable Energy has a directory of building energy software tools with nearly 400 vendors.

The listing can be found at this website: http://apps1.eere.energy.gov/buildings/tools_directory/.

To calculate total energy consumption, data must be collected from utilities bills and should include electricity, natural gas and any other fuel sources used in the plant. Energy estimates should account for all intended energy use, including regulated load assumptions such as equipment and systems, and non-regulated load assumptions such as plug loads, energy consumed by any electronic device plugged into a socket, and process loads.

HVAC consumption, lighting and mechanical systems, compressed air usage, domestic hot water, exterior lighting and other systems, such as elevators, are important considerations when determining real energy usage data for evaluation and setting goals for improvement. Actual operating schedules and right sized system numbers need to be used for accuracy.

Key steps include walking through the plant when not in operation to identify energy waste, checking hours of operation and settings on equipment, establishing a list of energy shut-down procedures, reviewing these with plant managers and employees, and periodically inspecting plant adherence to procedures.

Energy Star in the US and Build Up in Europe both offer tools for label converters to assess a whole building’s energy efficiency. Energy Star has a Portfolio Manager program that helps track a building’s energy use and water consumption over time and estimate its overall carbon footprint. The system works on a 100-point scale with 50 defined as average performance. Buildings that achieve a rating of 75 or higher are able to apply for the Energy Star in building label.

CALCULATING GREENHOUSE GASES

The building sector is responsible for one third of all GHGs emitted into the atmosphere. The life cycle of a building includes its construction, use and after-use phases. Calculating the carbon emissions of a converting operation is critical to advancing energy and resource reduction within the building.

COMMON CARBON METRIC

In November 2009 the world’s leading ‘green’ building groups, also known as Green Building Councils, including Australia, the UK and US, and the BRE Trust, agreed to develop a common global language for the measurement of the carbon footprint of buildings and to develop a common carbon metric. From this, The Common Carbon Metric, a UNEP SBCI project, is being piloted by the leading ‘green’ building rating tools, such as LEEDs and BREEAM.

A building’s operational phase accounts for 80-90 percent of overall emissions, so the Common Carbon Metric focuses mostly on this area. The metric assesses performance in two ways: at the building level, bottom-up, and at the regional or national level, top-down. Generally the industry should be more concerned about collecting data and calculating carbon emissions for their individual building(s). However, as the sustainability movement continues to advance, there is no doubt that a top-down approach to measure individual building emissions compared to other national and regional buildings of the same scale will be desired.

The actual reporting is done in weight of carbon dioxide equivalent (kgCO 2e) emitted per square meter per year ( kgCO e/m2/year) by building type and by climate region.

While the Common Carbon Metric is not a building rating tool, it is consistent with methods for assessing the environmental performance of buildings used globally, such as the GHG Protocol, supported by the World Business Council for Sustainable Development (WBCSD) and the World Resources Institute (WRI), and the ISO 15392:2008 Sustainability in Building Construction and general principles of ISO 14040/44:2006 on life cycle assessment.

The development of the Common Carbon Metric opened the door for BREEAM to work in partnership with the rating tools operated by Green Building Councils, creating a global reach to truly reduce any building’s impact on the environment.

Managing efficiency of a manufacturing site has great potential to cost-effectively reduce carbon emissions and energy consumption. If buildings use 40 percent of the world’s energy and emit 30 percent of the globes emissions, there is much room for reduction.

For this reason ‘green’ building practices are being more frequently adopted, including the creation and implementation of an energy policy.

Converters have a great opportunity to reduce environmental footprints of manufacturing buildings through smart grid integration, energy management policies, sourcing energy from renewable sources and using advance building management software to monitor, track and document progress.

Documentation is vital to provide brand owners and retailers a more transparent supply chain and will help to verify adherence to local legislation and sustainability scorecards. Preventative maintenance systems for building mechanics are key pieces to an effective energy policy and must be followed through regularly.

All these efforts will help reduce a converting operation’s total carbon footprint, reduce costs and provide employees and the surrounding community with a more sustainable atmosphere in the long term.

DEVELOPING AN ENERGY EFFICIENCY POLICY

To aid the label converter in the development of an energy efficiency policy, this article has put together an outline policy document that the converter can use, amend, update for his own use. This is set out below.

Energy efficiency policy

XYZ Label Converting Company is committed to being an industry leader in making the most efficient use of energy in production and non-production times.

The key elements of our strategy to achieve this are to:

• Constantly monitor environmental issues, standards and best practices so that we can implement where necessary and advise our customers accordingly
• Comply with all relevant environmental legislation
• Strive to improve our environment performance and are committed to  continuous improvement to create sustainable labeling solutions
• Care about the environment and aim to deliver certified green materials and printing solutions to our customers
• Minimize waste and eliminate waste disposal to landfill
• Actively promote recycling, both internally and amongst customers and suppliers.
• Encourage the efficient use of energy, utilities and natural resources
• Minimize toxic emissions and use an accredited program to offset greenhouse gas emissions generated by our company
• Be assessed regularly by independent auditors to ensure we meet (ISO, LIFE, EMAS FSC, etc) or exceed environmental standards
• Invest in the necessary time and resource to provide environmental training for employees and enlist their support in improving the Company’s performance
• Support the education of consumers, the public and government in regard to the environmental profiles of our products and services 
• Promote environmental awareness in the community
• Measure our impact on the environment and set targets for ongoing improvement

CASE STUDY – WATER RECOVERY

California-based Paragon Label, the 2010 Global Green Award winner, installed a water treatment system in its building in 2001. The system, a batch treatment process cycle, recovers the wastewater from the printing process in an equalization tank. The treatment system periodically transfers a fixed volume of wastewater into the chemical treatment tank.

The tank stores up to 3,000 gallons of waste water at a time, releasing polymers that attach to any solids in the container. When the water is drained, it leaves only those solids which cause no harm when disposed of in a landfill.

Treatment chemicals are automatically added in a sequential fashion to the wastewater to separate selected contaminants from. These selected contaminants coalesce into a floc which is separable from the water. After the chemical treatment cycle, the contents of the treatment tank are filtered to separate the floc from the water.

Automatic operation begins by operating the air sparge system. The air sparge system will mix the contents of the equalization tank before proceeding to fill the chemical treatment tank. Wastewater to be treated will be transferred to the chemical treatment tank. The treatment tank mixer and recirculating/sludge transfer pump will then be activated. The chemical treatment process begins with the addition of coagulant which lowers the pH to break the emulsion in the water.

After the addition of the coagulant, the pH controller will add sufficient pH adjustment fluid (lime slurry solution) to the contents of the treatment tank to adjust the pH to the desired level for discharge into the city sewer system. The pH adjustment fluid is added to adjust the pH and conditions the sludge for processing through the filter press. The ideal pH is determined at the time of installation according to city discharge limits. The poly V 100 is then added to capture metals that are in the wastewater.

The last step in the chemical treatment process is the addition of a polymer which enlarges and encapsulates the floc formation for filtration.

After the chemical treatment cycle is over, the system will begin to transfer the contents of the treatment tank to the filter press. The recirculation/sludge transfer pump will be activated, pumping the treated water containing the enlarged floc through the filter press. The filter press will capture the floc and form a filter cake. The clean, treated water will flow through the collection channels in the filter press and will be collected in a filtrate holding tank.

A level-controlled transfer pump will periodically empty the contents of the filtrate holding tank into the sewer collection point. The automatic control system senses when the filter press is full and prompts the operator when it is ready to be blown down. The automatic control system circulates air through the filter cake in the press to minimize its moisture content. After the blow down phase the filter press is ready to be emptied. The operator opens the filter press and separates the filter plates and the filter cakes fall off into the sludge carts underneath.

These implementations, combined with numerous others on the exterior of the building, allowed the architect to reduce the size of the mechanical system, thereby further reducing energy consumption (the bigger the system, the higher the consumption).

Specific design elements were implemented to reflect the connection between the building and product and packaging development. For example, the concrete floors are made up of recycled content stripped from consumer product waste such as plastic bottles. The project has received an innovation credit for having over 30 percent recycled content within the building, including the furniture. Even on-site benches and mulch were harvested from trees on the plot of land. Water is recycled through a bio-swell.

The building received another innovation credit because more than 30 percent of the supplies used were regional materials. The majority of the project’s materials are made in South Carolina – including the bricks, concrete and steel. This, combined with locally contracted business, significantly reduced the CO2 emissions during the project’s completion.

Since 2009, the Green Building Certification Institute (GBCI), which includes a network of ISO-compliant international certifying bodies, has been the independent, third-party auditor, established in 2008, to administer LEED project certifications. The GBCI oversees the certification process of all international LEED projects to give multinational businesses the ability to embrace ‘green’ building across an entire portfolio. It accounts for regional differences to provide global consistency and to provide the ability to benchmark across borders.

The Rating Systems with international options became available at the beginning of 2011. It is supported by the LEED International Roundtable that consists of representatives from national ‘green’ building councils and organizations around the world. Wisconsin-based converter Lauterbach Group and Toronto-headquartered converter Metro Label have achieved LEED certification at some of their facilities.

Lauderbach Group comments on its LEED sustainable building certification: ‘The old adage that it costs more to do this stuff is more of a fallacy. The investments that we made in the building were quick paybacks.’

In early 2011, P&G pledged to pursue LEED sustainable building certification for all of its new sites globally. Its Taicang, China, plant will be the first of its manufacturing sites to pursue LEED certification.

Note that acute studies on LEED certified building energy consumption have revealed that while LEED buildings consume as much as 35 percent less energy per square area when compared to traditional constructions, as many as one third of certified buildings consume more energy than conventional buildings.

BREEAM – UK - The UK’s BRE (Building Research Establishment) established the BREEAM (BRE Environmental Assessment Method) scheme in 1990 and has since certified over 10,000 buildings worldwide. BREAAM also offers global opportunity, with structures that include Europe and BREEAM Gulf. All address the specifications inherent to each nation or region.

Since 2008, a number of European countries have validated the BREEAM International framework through their official bodies. Among them is the Netherlands, validated by the Dutch Green Building Council, which launched its locally adapted version of BREEAM NL in October 2009. Ireland, Spain, Latvia, Turkey, Norway, Sweden, Russia, Poland and Bulgaria have partnered with the rating system and are in the process of adapting it through their respective national Green Building Councils and building stakeholder leaders.

The partnership objectives are to develop versions of the program available in the local language and managed locally to ensure national ownership within the overall international framework. The development of the Common Carbon Metric opened the door for BREEAM to work in partnership with the rating tools operated by Green Building Councils, creating a global reach to truly reduce any building’s impact on the environment.

Green Globes - In 1996, the Canadian Standards Association (CSA) published ‘BREEAM Canada for Existing Buildings’. In 2000 the scheme transformed into an online assessment and rating tool under the name Green Globes for Existing Buildings, and quickly developed an Existing Buildings program with federal support. The Building Owners and Managers Association of Canada (BOMA) adopted Green Globes for Existing Buildings in 2004 and acquired rights to distribute in the US. Green Globes is accredited by the American National Standards Institute (ANSI).

CSTB – France - In June 2009 France’s CSTB (Centre Scientifique et Technique du Bâtiment) and its subsidiary CertiVéA signed a memorandum of understanding to work with the global arm of BREEAM to develop a pan-European building environmental assessment program. The program is similar to the French HQE (Haute Qualite Environmentale), which is the standard for ‘green’ building in the country; however, there has not been much progression of the project since the agreement

Green Star – Australia - Australia’s Green Star environmental rating system for buildings was launched in 2003 by the Green Building Council of Australia (GBCA). The GBCA has played a prominent role in the WorldGBC. In 2006, the GBCA worked collaboratively to support the establishment of the Green Building Council of New Zealand and more recently the Green Building Council of South Africa. Both councils have adopted the Green Star rating tool and modified it for the unique conditions of their own countries.

WATER RECOVERY SYSTEMS

Water usage is an important part of a building’s overall efficiency. Active water conservation can save building consumption and demand charges.

The investment cost is comparatively low and the return on investment quick when proper evaluation is applied.

Making simple changes around the building to faucets, toilets and urinals to low flow systems can show a significant reduction in water usage. Graywater is waste water from showers, sinks, washing machines and tubs.

Depending on local regulations, two separate recovery systems – graywater and blackwater – can be used and treated appropriately. Graywater can be more simply recovered and reused in toilets, irrigation systems, chillers and for other non-potable water uses.

Graywater is distinct from blackwater, which comes from sources that contain toxic or organic matter like food. Blackwater, which is produced in many label and packaging production plants, can be recovered, treated properly and dispelled into the system in accordance with local regulations for reuse. Water recovery systems reduce manufacturing strains on local water resources and ensure that contaminated water is not sent into the surrounding water table.

Paragon Label only uses water-based inks and, according to current environmental regulations, these inks can be washed down the drain. Still, the company actively chooses to reduce its strain on the California sewer system and to further reduce its environmental impact. The converter says that with the recovery system, water discharged from the facility is cleaner than the water coming in.

Rainwater recovery is another way to conserve water in and around a manufacturing plant. There are simple and complex systems that can be designed for a new building structure, or that can be retrofitted to work on an existing building.

In order to capture rain water for storage and reuse, there needs to be a designated area to recover water, known as the catchment area. This can be as easy as a barrel under a spout, a flat top roof, a parking lot or a patio. Most importantly, the material used to collect the water – concrete, metal, etc – should not contaminate it upon collection. Once a collection location is established, an infrastructure must be created to lead the water to a storing point where it can be cleaned, if necessary, and saved until use in specific areas within the building, or externally for irrigation.

CASE STUDY – WATER RECOVERY

Clemson University’s Sonoco Institute for Packaging Research captures water to be recycled through what is called a ‘bio-swell’. This captures the majority of the water on site and filters it before it returns to the water supply. This feature, along with various other water flow reduction systems within the building, gave it a minimum of a 40 percent reduction in water usage. A LEED innovation credit was awarded as a result.

ENERGY CONSERVATION IN THE LABEL PLANT

Eighty-two percent of all greenhouse gas emitted by human activity, which includes walking, driving a vehicle and manufacturing, is energy-related carbon dioxide. Manufacturing makes up about 80 percent of industrial energy consumption, which also accounts for an estimated 80 percent of industrial energy-related carbon emissions. The global energy demand is forecast to grow by 57 percent in the next 25 years and around 30 percent in the US and Europe.

MODERATE ENERGY USAGE

Lowering a facility’s peak demand is a key step to improving load factor and will reduce the amount paid per kWh for electricity for customers on a demand rate structure. Look at how and when you use electricity to find ways to control your load factor. Install higher efficiency lighting or air conditioning. Scheduling or staggering large electric loads so they don’t start simultaneously may also help. It is important that energy consumption is addressed during unoccupied hours as well as operational periods.

The most important preparation step is to create a formal energy policy with a commitment to continuous improvement. Industry leaders must realize that a formalized energy consumption policy can fight inflation problems, provide global economic independence, enhance competitive advantage, save money and energy, reduce greenhouse gas emissions, alleviate business demand on the grid and meet the Sustainability Scorecard requirements of brand owners and retailers as described.

CREATING AN ENERGY POLICY

An Environmental (Energy) Management System (EEMS) will generally include some or all of the following elements, and is similar to a standard EMS;

• The writing of an energy policy statement

• Setting out the organizational management structure to implement the energy policy

• Providing information about personnel and job responsibilities

• Setting out what the energy review and energy planning process will contain

• Developing guidelines on the practices, procedures and processes to be used

• Providing information on the resources being made available for developing, implementing, checking and achieving the EEMS

• Establishing procedures for reviewing, maintaining and improving the environmental (energy) management system and policy, plus management reporting

An example of an environmental energy efficiency policy is shown at the end of this articles. 

IMPLEMENTING AN ENERGY POLICY

There are a number of important steps to be undertaken in implementing a label converter energy policy. These can be seen in Fig 4.6.

These steps are now examined in more detail.

Dedicate energy management squad - The first step to instituting an energy management program within a label converting operation is to appoint a dedicated energy team to collaborate and introduce an energy policy, and track, modify and improve it to be most effective. The energy team will execute energy management initiatives across various parts of the organization in production – pre-press, Define whole plant energy usage baseline press room manufacturing, finishing and delivery – and in office space and exterior areas of the manufacturing facility.

Define baseline - The energy team must assess current and past energy performance of manufacturing operations and the facility as a whole.

Opportunities to improve energy performance and gain financial benefits must be identified by cross-evaluating energy use across all facilities and functions within label manufacturing operations. The ultimate goal is to establish a baseline by which future usage can be measured and compared.

Create energy policy - Once a label converter has a dedicated energy team and a baseline established, an energy policy must be designed to set performance goals and establish energy management measures that best align with its particular converting operation and business culture.

Plant energy assessment - Once a baseline has been established, the energy team can begin performance assessment evaluations, collecting energy usage data over any given period of time, typically per quarter. These performance evaluations are used to identify time periods of higher energy consumption and energy use by fuel type, and to recognize manufacturing machinery and building systems that could be improved.

Performance goals drive energy management activities and promote continuous improvement. Setting clear and measurable goals is critical for understanding results, developing effective strategies and reaping financial gains.

Establish goals, timelines - Estimate potential for improvement. Review baselines and determine the potential and order of upgrades. Conduct technical assessments and audits.

Take action - With goals in place, an organization is prepared to develop a roadmap to improve energy performance. Success is best achieved using a detailed action plan, which, unlike the energy policy, is regularly updated, most often on an annual basis, to reflect recent achievements, changes in performance and shifting priorities.

Measure and monitor - Use the tracking system developed as part of the action plan to track and monitor progress regularly. Evaluating progress includes formal review of both energy use data and the activities carried out as part of the action plan as compared to your performance goals.

Evaluation results and information gathered during the formal review process can be used to create new action plans, identify best practices, and set new performance goals.

People will determine the success of an energy program, so gaining the support and cooperation of key staff at all levels within the organization is an important factor for successful action plan implementation in many organizations. In addition, reaching your goals frequently depends on the awareness, commitment and capability of the people who will implement the projects. Details of the action plan must be regularly communicated to employees in all areas of the operation and should have established roles for all staff to participate and have their contributions be recognized.

ENERGY SOURCES

The three components of a complete electrical power grid include generation, transmission and distribution of electrical power. With the rising cost of energy and increased demand with a limited capacity, it makes sense in many cases to review the possibility of distributed generation.

Distributed generation comes from smaller entities outside of the utilities companies that privately produce energy to reduce the strain on the main grid. In some cases, excess energy produced can be sold back to local utilities companies or financial incentives can be found by participating in the utility company’s Demand Response program that rewards businesses willing to reduce their demand load during peak time periods.

In the US, generation typically constitutes half to one third of a bill. T&D is the remainder and in many cases is high because of demand charges and/or demand ratchets. Buying generation and energy efficiency are only two elements in reducing costs; demand needs to be monitored and controlled if possible.

Rising awareness of the strain on the globe’s electrical grids, the depletion of energy fuel sources, rising costs and rapidly increasing demand has the world scrambling to create solutions to these problems.

With the incorporation of digital technology into an electric grid system, a smart grid that allows for two-way communication between the utilities company and the consumer is gaining popularity. Unlike the current single directional grid system, a smart grid can monitor and control appliances within the home or business, assisting utilities companies in meeting the demands of the population, while at the same time empowering the general consumer and business leaders to control their individual effect on the grid and reduce their home or business’ carbon footprint.

Private funding and US legislation such as the Energy Policy Act of 2005 and Title XIII of the Energy Independence and Security Act of 2007 promoted the idea of a smart grid, but has not gained much traction in the wake of the global 2009 recession. As set in 2010, the European Council is not on track to meet its 20 percent energy efficiency target for 2020; however, in a meeting held on February 4, 2011, legislative action was called to assist in meeting this goal and to speed up the construction of an interconnected and fully integrated internal energy market for the region.

Typically, energy is stored in large amounts on the grid, saving excess production at times of low demand for when production cannot meet consumption. This allows the entire process of energy production and distribution to remain relatively constant. Energy grids that are connected to intermittent resources like wind and solar can realize significant cost benefits by depending on these renewables to support consistent supply with the rise and fall of demand.

Intermittent resources are those that are not continuously available and capable of being dispatched to meet demands of a power system. These sources are most often used to displace the fossil fuel required for most common energy production – coal, nuclear, geothermal, solar thermal and biomass.

RENEWABLE ENERGY/ALTERNATIVE ENERGY

Renewable energy, or alternative energy, is naturally sourced and replaced seamlessly, such as the sun’s light, wind, rain, tides and geothermal heat. In 2008, about 19 percent of global final energy consumption came from renewable sources.

Global renewable energy capacity advanced in 2009, when both the US and Europe, for the second consecutive year, increased power from renewable sources more than conventional sources like coal, gas and nuclear. UNEP reported that 60 percent of newly installed capacity in Europe and 50 percent in the US was from alternative options.

In 2009 renewable sources represented 25 percent of global power capacity (1,230 gigawatts (GW) of 4,800 GW total) and 18 percent of global power production. Wind power has consistently grown 30 percent annually around the world for some years. Global investment in wind power grew from $59b or 45 8%.

Most of the industry’s leading ink suppliers are taking sustainability seriously in a variety of ways. Some have established sustainability reports that provide details about what the company is doing internally, providing more transparency for converters through the supply chain. Others are working with third-party auditing firms to validate their sustainability programs and certify various products to environmental credibility. They are introducing new inks and researching and developing the advancement of renewable content products.

Sun Chemical is in its third year of sustainability accounting and is constantly investigating how it can lower its total carbon footprint. It has developed SunCare in cooperation with EnviroN, a third-party support line specializing in sustainability, to provide environmental consultative assistance to its customers. The ink supplier also provides product life cycle data, currently reporting only on its gate-to-customer-gate data. Taking its analyzes a step further, it will soon begin to evaluate its own supply chain.

BASF eco-efficiency analysis - Chemical company BASF, a producer of ink resins, in 2008 compiled an eco-efficiency analysis for flexographic inks in film applications. An eco-efficiency analysis compares both the economic and environmental impacts that a product or process has over the course of its life cycle.

The study compared water-based, solvent and UV printing inks with 25 percent image coverage on 0.003mil film. Each product was weighted in six environmental categories – land use, energy consumption, emissions, toxicity potential, risk potential, resource consumption – against cost. In the end, the research concluded that water-based inks are the most environmentally friendly, lower-cost choice of the three flexographic inks.

The BASF study was completed on a CI press in the midwestern United States. The study found that solvent-based ink consumed the most energy throughout the entire cycle, mostly due to the chemistry involved in the ink formulation. Solvent-based inks were also found to use the highest amount of natural resources while water-based and UV inks consume relatively the same.

When looking closely at emissions or the possible Global Warming Potential (GWP), UV-curable inks were found to have the most negative impact because of electricity usage, which is more inefficient than gas.

ECO-INKS

Using inks which have all heavy metals eliminated from their formulas and which contain only trace amounts of VOCs is a step to becoming more environmentally friendly. Many alternatives to solvent-, water- and UV-based inks have recently hit the market, including soy and corn-based products and percentage renewable content, which effectively reduce emissions without compromising quality.

The National Association of Printing Ink Manufacturers offers a verifiable certification of the Bio-derived Renewable material Content (BRC) of ink.

BRC is dependent on the printing process and application due to the physical/chemical requirements of the printing press and the means used to dry the printed ink film. Therefore, BRC values cannot be compared between different ink types. Each ink type has its own range of potential BRC.

Vegetable-based ink serves as an appropriate replacement of traditional petroleum-based ink for lithographic and letterpress printing. The US Department of Printing uses only ink with a non-toxic vegetable oil base, which contains a combination of soy, cottonseed, corn and other vegetable oils. The ink virtually eliminates toxic air emissions and hazardous waste, improves indoor air quality and qualifies as a renewable resource.

The Flint Group offers BioCure F UV curable flexographic inks made up of 10 percent renewable linseed oil acrylate in replace of traditional resin. It also has a water-based AquaSoy line with a resin made of soybeans farmed specifically for alternative sources. The American Soybean Association has created the Soy Seal which verifies that water-based flexographic inks have at least 15 percent of the resin from soybean oil.

Zeller+Gmelin too offers its Nuvaflex 35 Series of 20 percent renewable content UV flexographic inks, including an opaque white. The company claims that the inks release less than one percent VOCs when polymerized.

Nazdar has a water-based line of caustic soluble inks for reusable bottles, much favored by the Latin America beer market and other beverage sectors in the region. This soluble ink washes out in caustic solution without harming the integrity of the paper label waste stream, a very important aspect when reviewing a product’s life cycle impact

INX has certified a line of its sheet-fed inks to EcoLogo, an environmental standard and certification mark established in 1988 by the Canadian government, but is now used globally. EcoLogo meets the ISO 14024 standards for eco-labeling.

WATER-BASED AND UV

Aqueous, or water-based, coatings are used to protect printed items from damage such as scratches and fingerprints. Unlike traditional petroleum-based coatings, aqueous coatings do not produce any hazardous emissions and are considered non-toxic.

Water-based inks should be used wherever possible – flexography, gravure, offset and screen printing. While some printers claim quality faults with using water-based inks, many report vivid color produced on a variety of materials, more consistent viscosity throughout a print run and better coverage, which reduces the amount consumed and therefore reduces costs.

There are a number of reliable suppliers, international and regional, that provide dependable water-based inks. For example, Actega WIT offers a water-based bright metallic ink designed to have extended shelf and press stability as well as advanced trapping capabilities. It also has water-based gloss and matte finish varnishes for the wine label market.

The difficulty with using water-based inks is the required drying time. UV inks are cured with the use of a UV light, curing a mostly solid ink film and almost eliminating the release of VOCs from the ink content into the air. However, they require the use of acrylate resins, which are irritants. UV radiation can be damaging to the skin, produce ozone from atmospheric oxygen and consume reasonable amounts of energy.

INK CONTAINER RECYCLING

A number of label and packaging converters, with the support of their ink suppliers, are reducing, reusing and recycling inks and the containers they are delivered in. INX offers customers ‘A Basic Guide: Customer Waste Management Options’ as a tool to reduce their waste and carbon footprint for this production aspect.

The guide informs customers of the recyclability of its plastic ink containers and the various outlets available, including commercial and industrial recycling programs and waste to energy by incineration. It explains that national and regional facilities will collect the containers, but that each may have different standards for cleanliness, scraped versus triple rinsing, so it is important to check with local firms for specific criteria. The INX guide provides a basic grid for converters to evaluate which recycling stream will work best for their operations.

ENERGY REDUCTION IN UV AND DRYING SYSTEMS

UV curing refers to the way in which coatings, inks and adhesives are dried using energy from UV light radiation sources rather than conventional heat. The traditional UV lamp curing system consists of lampheads, reflectors, cooling systems and an electrical/electronic source.

The most common type of UV lamp is mercury vapor because it offers the broadest arc spectrum. There are also metal halide doped lamps where the mercury is mixed with iron or gallium to modify the spectrum range. Typically it is recommended to use a mercury vapor lamp for any possible curing application because it has more longevity than halide versions and typically less expensive.

Sophisticated electrical systems are used to ignite, warm up and operate high intensity, medium-pressure mercury vapor lamps. Each lamp requires high voltage to initiate the arc and a lower voltage to maintain it during operation.

To ensure constant curing speeds, the electrical system is power-regulated by a three-phase voltage stabilizer or ballast. A stabilized system supplies constant power to the lamp even with variations in the line voltage. Infinitely variable output power provides finite control and efficient running of UV lamps.

In most cases, one ballast is required to operate one mercury lamp. Each ballast supplies constant power to the lamp. Lamp power variation will not exceed + 3 percent with line voltage fluctuations of up to + 10 percent. As supplied, the ballasts will operate the lamps at full power. However, operation at 75 percent or 50 percent output is possible by use of a capacitor-switching network. Switched-capacitor networks allow for electronically variable resistors, with no moving parts, which makes the voltage input adjustable as compared to standard resistors. Ballasts are available in a variety of input voltages and for operation on either 50 or 60 Hz.

The output voltage from a transformer/choke ballast type supply is approximately sinusoidal at 50-60Hz. The lamp UV output is dependent on the magnitude of the input voltage, hence it is pulsed at double the input voltage frequency. Three-phase input, balanced under all load conditions and stabilized constant UV output during main voltage fluctuations (within 370-480V, 50-60Hz).

A rectangular current output causes an approximately 10 percent greater UV yield for the same electrical power compared to the sinusoidal power output of a conventional transformer/choke ballast. Typical lamp output varies at 100-120Hz.

Low power and high power systems can cure many label applications with 140W/cm, yet many of the more complicated unsupported film applications will require curing at 200W/cm to the substrate.

GEW was the winner of the first annual Global Green Award at Labelexpo Europe 2009. All supplier submissions for the award are cross-evaluated using five factors: pollution reduction/prevention, environmental leadership and economic effectiveness as well as relevance to the industry, responsible sourcing and potential for advancement.

GEW was selected for its e-System UV ink curing equipment. Its e-System, e-Brick lamp control and power supply boost UV output by 20 percent by incorporating high-voltage, high-frequency square-wave technology. This control also gives more overall curing consistency. At the same time, it reduces running power for a comparable curing system by 30 percent. The system decreases CO2 emissions by 30 percent while extending lamp life, bringing significant cost savings to users. The e-System can be incorporated into any press type and has multiple installations around the world.

Compared with conventional UV curing technologies, the e-System range of electronic power supplies and optically perfected lampheads has had the potential to have collectively saved customers an estimated 35.700 tonnes of carbon dioxide emissions and 8.6 million euros when compared to conventional transformer/choke ballast supplied UV curing systems.

The e-Brick is compact, lightweight and stackable, with less than 30 percent of the volume and 20 percent of the weight of conventional systems, reducing shipping size, weight and cost. The output voltage from an e-Brick is square wave at 300Hz.

UV lamps emit heat during use, so a cooling component is required. UV lamps can be cooled by air extraction or water-cooled. It is important to ask suppliers which cooling system works most effectively for the products produced on press. In many cases air extraction systems can incur higher costs as opposed to water.

UV output automation - GEW introduced an automatic control system for the UV output level of its e-Brick systems to work in direct proportion to the press speed. With the use of an integrated control program, diagnostic features are monitored to optimize UV output, enhance lamp longevity and the UV curing system’s overall performance. With the automated system, the company aims to help its customers further reduce energy costs and prevent spoiled print jobs by using the minimum power required to cure, with extra in reserve for the more difficult jobs.

Using the system, GEW customers can select the power level required for the job depending on the properties of the ink, coating or adhesive at the appropriate press speed. Rather than being manufacturer-set, users are now able to select whatever power they need to print a specific job, while being assured of the highest level of energy efficiency.

UV systems are frequently left on stand-by between runs, shift changes and break periods, so they are ready for operation when the operator wants to start producing an order. An intelligent GreenTimer automatically switches the system on and off, documenting peak and low period usage so cost savings can be easily quantified.

Whether lamps are cooled by compressed air or water systems, maintenance and cleaning should be scheduled on a weekly or bi-weekly basis depending on press and system usage.

LED CURING

UV LED curing technology, which is mercury-free, does not generate ozone harming emissions and new developments are allowing for accelerated production speeds, lower production costs and reduced energy usage compared to traditional lamps. While it is rising as an option for alternative curing, many inks formulated for the industry have not been developed to optimize cure with this technology.

Phoseon’s ELC line of electronic power supply units operates with low energy input. The UV unit can be operated in stand-by mode with lamp output of 20-30 percent. The system is equipped with output control for consistency and accurate temperature control. An integrated control and monitoring system allows the unit to operate consistently under network voltage variations of ±10 percent.

LED curing can perform cure of inks and coatings on heat-sensitive substrates without distortion. The lamp can be switched to energy-saving stand-by mode and the lamp output can be automatically adjusted between 25-100 percent depending on the print speed. The ELC range lamp outputs from 4kW to 32kW.

Phoseon’s patented Semiconductor Light Matrix technology uses high power UV LED technology with semiconductor arrays that can be turned on and off during the manufacturing process. The LEDs do not produce excess heat and can be disposed of as regular waste, whereas UV lamps with mercury become hazardous materials at the end of their life cycle.

Note that all modern UV curing systems are able to automatically switch into stand-by mode when the press is not in production where the power level is between 18-50 percent of full power.

Mark Andy and Flint Group have championed LED-UV for flexo presses, while digital applications typically include inter-color pinning. EFI Jetrion launched an inkjet press using LED-UV for final cure at Labelexpo Americas 2014.

SUSTAINABLE PRESS ENGINEERING

Label press manufacturers have done a considerable amount of work in recent years to make label printing equipment more sustainable, to reduce set-up and running time, to reduce press running waste and to re-engineer press technology taking into account life cycle considerations.

Gallus, for example, has reviewed the environmental conditions of label printing machinery and press rooms, assessing environmental interfaces and looking at where waste reduction, energy efficiency, noise and heat occur in the press environment.

These areas can be seen in Fig 4.16.

Taken further, this has enabled Gallus to look at areas of energy consumption on a label printing press (see Fig. 4.1) and then work on each of these areas to convert sustainability into an economic benefit in the press design. As can be seen in the diagram, UV drying has traditionally been a large area of energy consumption on a label press. Now, with the Gallus ECS 340 UV-curing system without exhaust and the newest reflector and lamp technology, energy costs have been reduced by up to 10,000 euros per annum, ozone discharge into the environment has been eliminated and, thanks to centralized water cooling of the machine and UV-curing system, a temperature potential of two to three single-family homes is accessible for a heat exchanger solution.

In terms of press design, the Gallus RCS 340, for example, has been designed with a short web path, which is claimed to reduce the total web in the machine from approximately 50 meters down to 12 meters. This in turn is said to reduce production waste by around 10 tonnes per annum, and a cost saving of 40,000 euros per annum.

Functional press design can both help to reduce energy costs for manufacturing and significantly shorten press manufacturing lead time. Historically, says Gallus, a printing unit would be built out of some 300 parts; today, the newest generation consists of just 90 parts.

While these examples of more sustainable press design have been taken from examples given by Gallus, most leading label press manufacturers will be working towards similar or alternatives approaches to press sustainability, energy efficiency and waste reduction in their latest generation of presses.

Label converters utilizing these latest designs of label presses, and implementing other label manufacturing efficiencies such as automatic inspection, sophisticated ink dispensing systems, new cutting technology and a commitment to recycling, can today achieve significant cost savings. This can be seen in the following case study.

WHOLE-BUILDING ENERGY CALCULATION

Many methods and tools are available to perform an energy analysis in order to create a baseline for a label and packaging converter’s energy policy. There are a number of computer simulation software programs available for both new building design and for established manufacturing sites, as well as various online energy calculators that focus on specific regions and energy sources.

The US Department of Energy, Energy Efficiency and Renewable Energy has a directory of building energy software tools with nearly 400 vendors.

The listing can be found at this website: http://apps1.eere.energy.gov/buildings/tools_directory/.

To calculate total energy consumption, data must be collected from utilities bills and should include electricity, natural gas and any other fuel sources used in the plant. Energy estimates should account for all intended energy use, including regulated load assumptions such as equipment and systems, and non-regulated load assumptions such as plug loads, energy consumed by any electronic device plugged into a socket, and process loads.

HVAC consumption, lighting and mechanical systems, compressed air usage, domestic hot water, exterior lighting and other systems, such as elevators, are important considerations when determining real energy usage data for evaluation and setting goals for improvement. Actual operating schedules and right sized system numbers need to be used for accuracy.

Key steps include walking through the plant when not in operation to identify energy waste, checking hours of operation and settings on equipment, establishing a list of energy shut-down procedures, reviewing these with plant managers and employees, and periodically inspecting plant adherence to procedures.

Energy Star in the US and Build Up in Europe both offer tools for label converters to assess a whole building’s energy efficiency. Energy Star has a Portfolio Manager program that helps track a building’s energy use and water consumption over time and estimate its overall carbon footprint. The system works on a 100-point scale with 50 defined as average performance. Buildings that achieve a rating of 75 or higher are able to apply for the Energy Star in building label.

CALCULATING GREENHOUSE GASES

The building sector is responsible for one third of all GHGs emitted into the atmosphere. The life cycle of a building includes its construction, use and after-use phases. Calculating the carbon emissions of a converting operation is critical to advancing energy and resource reduction within the building.

COMMON CARBON METRIC

In November 2009 the world’s leading ‘green’ building groups, also known as Green Building Councils, including Australia, the UK and US, and the BRE Trust, agreed to develop a common global language for the measurement of the carbon footprint of buildings and to develop a common carbon metric. From this, The Common Carbon Metric, a UNEP SBCI project, is being piloted by the leading ‘green’ building rating tools, such as LEEDs and BREEAM.

A building’s operational phase accounts for 80-90 percent of overall emissions, so the Common Carbon Metric focuses mostly on this area. The metric assesses performance in two ways: at the building level, bottom-up, and at the regional or national level, top-down. Generally the industry should be more concerned about collecting data and calculating carbon emissions for their individual building(s). However, as the sustainability movement continues to advance, there is no doubt that a top-down approach to measure individual building emissions compared to other national and regional buildings of the same scale will be desired.

The actual reporting is done in weight of carbon dioxide equivalent (kgCO 2e) emitted per square meter per year ( kgCO e/m2/year) by building type and by climate region.

While the Common Carbon Metric is not a building rating tool, it is consistent with methods for assessing the environmental performance of buildings used globally, such as the GHG Protocol, supported by the World Business Council for Sustainable Development (WBCSD) and the World Resources Institute (WRI), and the ISO 15392:2008 Sustainability in Building Construction and general principles of ISO 14040/44:2006 on life cycle assessment.

The development of the Common Carbon Metric opened the door for BREEAM to work in partnership with the rating tools operated by Green Building Councils, creating a global reach to truly reduce any building’s impact on the environment.

Managing efficiency of a manufacturing site has great potential to cost-effectively reduce carbon emissions and energy consumption. If buildings use 40 percent of the world’s energy and emit 30 percent of the globes emissions, there is much room for reduction.

For this reason ‘green’ building practices are being more frequently adopted, including the creation and implementation of an energy policy.

Converters have a great opportunity to reduce environmental footprints of manufacturing buildings through smart grid integration, energy management policies, sourcing energy from renewable sources and using advance building management software to monitor, track and document progress.

Documentation is vital to provide brand owners and retailers a more transparent supply chain and will help to verify adherence to local legislation and sustainability scorecards. Preventative maintenance systems for building mechanics are key pieces to an effective energy policy and must be followed through regularly.

All these efforts will help reduce a converting operation’s total carbon footprint, reduce costs and provide employees and the surrounding community with a more sustainable atmosphere in the long term.

DEVELOPING AN ENERGY EFFICIENCY POLICY

To aid the label converter in the development of an energy efficiency policy, this article has put together an outline policy document that the converter can use, amend, update for his own use. This is set out below.

Energy efficiency policy

XYZ Label Converting Company is committed to being an industry leader in making the most efficient use of energy in production and non-production times.

The key elements of our strategy to achieve this are to:

• Constantly monitor environmental issues, standards and best practices so that we can implement where necessary and advise our customers accordingly
• Comply with all relevant environmental legislation
• Strive to improve our environment performance and are committed to  continuous improvement to create sustainable labeling solutions
• Care about the environment and aim to deliver certified green materials and printing solutions to our customers
• Minimize waste and eliminate waste disposal to landfill
• Actively promote recycling, both internally and amongst customers and suppliers.
• Encourage the efficient use of energy, utilities and natural resources
• Minimize toxic emissions and use an accredited program to offset greenhouse gas emissions generated by our company
• Be assessed regularly by independent auditors to ensure we meet (ISO, LIFE, EMAS FSC, etc) or exceed environmental standards
• Invest in the necessary time and resource to provide environmental training for employees and enlist their support in improving the Company’s performance
• Support the education of consumers, the public and government in regard to the environmental profiles of our products and services 
• Promote environmental awareness in the community
• Measure our impact on the environment and set targets for ongoing improvement

CASE STUDY – WATER RECOVERY

California-based Paragon Label, the 2010 Global Green Award winner, installed a water treatment system in its building in 2001. The system, a batch treatment process cycle, recovers the wastewater from the printing process in an equalization tank. The treatment system periodically transfers a fixed volume of wastewater into the chemical treatment tank.

The tank stores up to 3,000 gallons of waste water at a time, releasing polymers that attach to any solids in the container. When the water is drained, it leaves only those solids which cause no harm when disposed of in a landfill.

Treatment chemicals are automatically added in a sequential fashion to the wastewater to separate selected contaminants from. These selected contaminants coalesce into a floc which is separable from the water. After the chemical treatment cycle, the contents of the treatment tank are filtered to separate the floc from the water.

Automatic operation begins by operating the air sparge system. The air sparge system will mix the contents of the equalization tank before proceeding to fill the chemical treatment tank. Wastewater to be treated will be transferred to the chemical treatment tank. The treatment tank mixer and recirculating/sludge transfer pump will then be activated. The chemical treatment process begins with the addition of coagulant which lowers the pH to break the emulsion in the water.

After the addition of the coagulant, the pH controller will add sufficient pH adjustment fluid (lime slurry solution) to the contents of the treatment tank to adjust the pH to the desired level for discharge into the city sewer system. The pH adjustment fluid is added to adjust the pH and conditions the sludge for processing through the filter press. The ideal pH is determined at the time of installation according to city discharge limits. The poly V 100 is then added to capture metals that are in the wastewater.

The last step in the chemical treatment process is the addition of a polymer which enlarges and encapsulates the floc formation for filtration.

After the chemical treatment cycle is over, the system will begin to transfer the contents of the treatment tank to the filter press. The recirculation/sludge transfer pump will be activated, pumping the treated water containing the enlarged floc through the filter press. The filter press will capture the floc and form a filter cake. The clean, treated water will flow through the collection channels in the filter press and will be collected in a filtrate holding tank.

A level-controlled transfer pump will periodically empty the contents of the filtrate holding tank into the sewer collection point. The automatic control system senses when the filter press is full and prompts the operator when it is ready to be blown down. The automatic control system circulates air through the filter cake in the press to minimize its moisture content. After the blow down phase the filter press is ready to be emptied. The operator opens the filter press and separates the filter plates and the filter cakes fall off into the sludge carts underneath.

CASE STUDY – REDUCED PRODUCTION WASTAGE

Adhesive Print Limited in Auckland, New Zealand, is recognized as a global leader in self-adhesive label technology, production and application, and works to the ISO 9001:2008 quality standard and the ISO 14001 environmental standard. Waste in the company has been reduced to a minimum. Areas of waste reduction include:

• The use of an Inkmaker single point dispensing system to provide an instantly available unlimited color palette, reduced ink stocks and easy recycling of ink returns without wastage. As a result, the company removed ink waste from the production stream and now has 99 percent ink recovery

• The use of AVT PrintVision/Helios advanced 100 percent automatic inspection equipment which has taken production waste down by at least 50 percent and often nearer to 90 percent

• The use of industry-leading Interloc laser cutting technology which has given both material and time-saving economies in the production of irregular shaped-labels

• Investment in new Gallus printing technology that reduces set-up waste and uses fewer resources than previously

• Ensuring that all aspects of the business recycle wherever possible

• An on-going commitment to waste reduction, recycling and energy conservation in its manufacturing facilities in New Zealand and Australia

Energy efficiency policy

XYZ Label Converting Company is committed to being an industry leader in making the most efficient use of energy in production and non-production times.

The key elements of our strategy to achieve this are to:

• Constantly monitor environmental issues, standards and best practices so that we can implement where necessary and advise our customers accordingly

• Comply with all relevant environmental legislation

• Strive to improve our environment performance and are committed to  continuous improvement to create sustainable labeling solutions

• Care about the environment and aim to deliver certified green materials and printing solutions to our customers

• Minimize waste and eliminate waste disposal to landfill

• Actively promote recycling, both internally and amongst customers and suppliers.

• Encourage the efficient use of energy, utilities and natural resources

• Minimize toxic emissions and use an accredited program to offset greenhouse gas emissions generated by our company

• Be assessed regularly by independent auditors to ensure we meet (ISO, LIFE, EMAS FSC, etc) or exceed environmental standards

• Invest in the necessary time and resource to provide environmental training for employees and enlist their support in improving the Company’s performance

• Support the education of consumers, the public and government in regard to the environmental profiles of our products and services

• Promote environmental awareness in the community

• Measure our impact on the environment and set targets for ongoing improvement