Conservation in the printing industryOrganisations, standards, certificates and technologies for sustainable, green production

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Conservation in the printing industryOrganisations, standards, certificates and technologies for sustainable, green production

The heated debate on global warming and the expansion of theozone hole above the polar caps have heightened environmental aware-ness the world over. The members of the European Community andOrganisation for Economic Co-operation and Development justifiablysee themselves as pioneers in initiating preventative action and

establishing ecological standards. The impact on the print mediaindustry – which consumes a huge volume of forestry products andchemicals while emitting VOCs, dust, noise and heat – is manifold.This supplement examines the challenges facing printers, and theopportunities they offer.

Ecologyis a branch of biology studying the relationships between living organisms and theirenvironment. Man must view himself as part of this relationship and thus limit hisimpact on natural resources to a sustainable minimum. Plants and animals must begiven sufficient living space so that an ecological balance is maintained which will allowfuture generations of humans to enjoy an intact environment.

Sustainabilityis the term used to describe human activity that will have a neutral or positive long-termimpact on the environment. More specifically this refers to the preservation and care ofthe soil, water, air, habitats and other resources, and the substitution of fossil-based andslow-growing resources with renewable and fast-growing ones.

Reaping the reward for environmental engagement: Herbert Preissler (l), managing director of Druckhaus Berlin-Mitte, expressing his delight at winning the Druck&Medien award for themost environmentally focused enterprise of the year. Sponsored by KBA, the award was presented by Ralf Sammeck, KBA’s executive vice-president for sheetfed sales, following a decision by an independent 20-man jury. Druckhaus Berlin-Mitte, which has a number ofRapida presses, joined the Eco Management and Audit Scheme (EMAS), an initiative designedto improve companies’ environmental performance, in 2002 and obtained EN ISO 14001 environmental accreditation that same year

Consumption and emissionsThe print media industry’s special statusPaper consumption • The fact thatprinting is not usually possiblewithout paper, and that vast vol-umes of packaging are printed onother materials, has given theprinting and packaging industry aspecial status. Disposable printedproducts and packaging are thebiggest source of waste by a hugemargin. And despite the growthof e-media, our annual consump-tion of paper is rapidly rising. Sothe industry has an obligation toadopt sustainable productionmethods wherever possible.Press manufacturers can make amaterial contribution by develop-ing new technologies to cutpaper waste.Emissions • Printing presses can bepretty loud – the higher the num-ber of ink-splitting points, thelouder the press. Motors, gears,mobilised masses and com-pressed air all contribute to thegeneral noise. On web pressesthe folder is an additional sourceof noise.

The issues of ink mist, paperdust, powder, ozone, volatileorganic compounds (VOCs) andheat emissions must also beaddressed. The “VOC databasefor the German printing indus-try”, published by Ökopol in1999, ranked the printing indus-try among the biggest polluters,with emissions of 70,000 tonnesof VOCs per year (7%). Mostmanufacturers of presses, inksand chemicals have thereforecome to consider it their duty tohelp bring about a substantialreduction in emissions.

Status quo in the production chainPre-press • The introduction ofdigital workflows and direct imag-ing in offset, gravure and flexoprinting has rendered many envi-ronmentally critical processes

superfluous. Ozone-generatingcopying frames, silver-laden resi-dues and hazardous waste fromfilm development and platemak-ing are now a thing of the past inmany printing plants. In offset,chemistry-free plates are becom-ing more popular, the Presstekplates imaged on-press in KBA’s74 Karat and 46 Karat havingproven their performance formany years now.Planographic printing • In wet off-set, VOC emissions caused by theevaporation of isopropyl alcohol(IPA) from the fount solution arestill the biggest process-relatedissue. This can be addressed bytaking on board the technology to

reduce the alcohol content or usean alcohol substitute. Alcoholsubstitution is one of the benefitsafforded by KBA’s hybrid presses.But even though it may be recy-cled many times, fount solutionmust ultimately be disposed of ashazardous waste. In waterless off-set, where KBA’s keyless inkingunits have moved it ahead of thecurve, there is no fount solutionat all.

Ink mist is non-existent onwaterless presses like the KBACortina, and has been substan-tially reduced both on the com-pact Commander CT and onCompacta commercial web press-es by fitting a new type of film

roller. For quality reasons, onlytiny quantities of spray powderare used on Rapida sheetfed off-set presses, and the powder andpaper dust are extracted by anACS air-cleaning system in thedelivery. A lot of powder manu-facturers have voluntarily under-taken to minimise the proportionof finer grains.

VOCs in the cleaning agentsfor rollers and blankets areincreasingly being replaced byhigh-boiling mineral or vegetableoils, which can be reused follow-ing filtration. Sheetfed offset andcoldset inks are VOC-free, whilesome of the binding agents theycontain are manufactured fromrenewable resources (vegetableoils).

Thermally drying aqueouscoatings and heatset inks con-sumes a lot of energy. Heatsetoils are recovered when theexhaust emissions from after-burning systems are cleaned andused for heating or hot water.The ozone generated when inksand coatings are cured by radia-tion (UV, EB) can be extracted infull. Radiation sources are encap-sulated in opaque housings.Gravure • In the past few yearsthere has been a dramatic drop intoluene emissions from printinginks following the adoption oflow-toluene inks, encapsulationtechnology and recovery fromthe dryer air. So the airborneconcentrations of toluene foundtoday at most modern presses areno longer a health hazard. Fromthe environmental perspective,water-based inks are a poor alter-native because they can causefan-out and the drying processconsumes a lot of energy.Carcinogenic nitrobenzene coat-ings have been replaced by harm-less two-component solvent-based coatings similar to thoseused in flexo.

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Example of a VOC audit schemeVolume of high-VOC materials purchased Process-related VOC emissionsInk, coatings printing, finishingIPA exhaust purificationOther dampening additives ink residue, rags, chemical wasteCleaning agents cleaning (% emitted less % chemically destroyed)Total VOC input Total VOC outputVOC input less VOC output = “diffuse emissions” (cf % thresholds!)

Estimated volumes of ink consumption at which printing presses must comply with directive 99/13/EC on the limitation of VOC emissions (EC VOC-RL) Source: Ökopol 1999Press line Critical ink volume Total VOC emission*

Publication rotogravure > 15 tonnes/year > 25 tonnes/yearHeatset web offset > 30 tonnes/year > 15 tonnes/yearPackaging gravure, solvent-based > 10 tonnes/year > 15 tonnes/yearPackaging gravure, water-based > 60 tonnes/year > 15 tonnes/yearPackaging flexo, solvent-based > 10 tonnes/year > 15 tonnes/yearPackaging flexo, water-based > 60 tonnes/year > 15 tonnes/year* of which diffuse emissions: < 25% at 15 t/a, < 20% at 25 t/a

Ranking atmospherically relevant gas emissionsGlobal warming (greenhouse effect):1. CO2 (carbon dioxide); 2. CH4 (methane); 3. NOx (nitrogen oxide); 4. H2O, density< 0.6 kg/m3 (water vapour); 5. SF6 (sulphur hexafluoride)Impact on the ozone layer:1. CFCs (chlorofluorocarbons): destruction; 2. HC (hydrocarbons) plus NOx (nitrogenoxide): compression/enrichment,“summer smog”

VOC emissions generated in theGermany printing industry, byprinting process Source: Ökopol 1999Process Proportion*

Sheetfed offset 29%Packaging gravure 23%Commercial web offset (heatset) 17%Publication rotogravure 15%Packaging flexo 7%Screen printing 5%Newspaper web offset (coldset) 2%Continuous and letterpress 2%* Industry emissions: calculated 53,293 t,estimated 70,000 t = 7% of total annual emissions in Germany

Costly IPA in fount solutions is the biggestVOC issue in the printing industry and controlling or reducing the level of IPA candeliver substantial cost savings. The alcoholsubstitutes used in IPA-free print productioncost no more than IPA, and the higher initialcost of IPA controls (photo), modified water circuits or inking-unit temperature control is recouped in the long term. If the right procedures are followed, then dispensingwith alcohol does not impair quality

Photo:Technotrans

Letterpress • Conventional flexoprinting inks emit a number ofalcoholic and aromatic VOCs.The solvents are burnt off in theexhaust cleaning unit or recycledusing catalytic conversion. UVinks and coatings can be used asan alternative for printing onfilm, aqueous inks on paper andcorrugated board. Letterpressinks for packaging and labels areat the same stage of developmentas offset inks.Screen printing • Here the choice ofinks ranges from VOC-rich toVOC-free (water-based or UV cur-ing), depending on the substrateconcerned. Removing the stencilfrom the screen entails morewaste than cleaning the inkingunits.Digital printing • Electrophoto-graphic processes that entail drytoner emit particulate matter,though nowadays this is wellbelow the permitted thresholds.More critical is the emission ofbenzene, azo dyes and heavy met-als from uncertified toners. Mostof the ozone emitted when thephotoconductor drum is chargedis filtered out. Inkjet inks, evenUV-curing ones, are not VOC-free. They are based in part onparticularly dangerous solventssuch as ethyl acetate and butylacetate. For inkjet printing,water-based inks are the VOC-free alternative.Offline finishing • Alongside non-hazardous aqueous special-effectcoatings and UV coatings, lami-nating film is often used to coatsurfaces. Dry lamination, duringwhich VOCs are emitted, is in-creasingly being replaced by wet,thermal (pre-coating) and granu-lar (spray-on) lamination, whichis VOC-free. The VOC emissionsthreshold for the application of

adhesives is 5 tonnes per year.Conversion • The vapours emittedby aqueous dispersion, hotmeltand PUR adhesives must beextracted. Only unhardenedadhesive waste is classified ashazardous waste.

Environmental responsibility and liabilityLegal situationInternational law • The resolutionspassed by the EnvironmentDirectorate of the Organisationfor Economic Co-operation andDevelopment (OECD), of whichthe world’s 30 leading industrialnations are members, are bindingunder international law.European law • The environmentaldirectives issued by the EuropeanCommunity (EC) are also legallybinding, and in the course ofEuropean harmonisation must bereflected in the laws and statuto-ry regulations of the memberstates. Their legal foundation isliability for hazards relating toplant and equipment, which in-cludes liability under laws on theprotection of air, water and soil,pollutant thresholds (technicaldirectives on contamination,noise, vibration) and the handlingof chemicals and dangerousgoods.

National law • In the USA personalfreedom and inviolability havethe highest priority, which is whywarnings are more often issuedin place of prohibitions, even inmatters relating to environmentalprotection; some states, however,have draconic laws. In Switzer-land alcohol- and VOC-rich clean-ing agents are taxed progressively(VOC incentive tax) according tothe volume consumed (in litres).In Denmark and Sweden, water-less offset has been adoptedmore extensively than elsewhereas a result of draconic VOC emis-sions thresholds and a ban onchlorofluorocarbons (CFCs) ascoolants in fount solutions. Thesuperior quality that waterlessoffset can deliver is evidenced bythe numerous KBA Rapida press-es and, more recently, theCortina heatset newspaper pressin operation there.Liability risks and hierarchy • Printproviders’ liability in respect ofenvironmental issues is definedin civil law (which includes com-mercial and labour laws) andcriminal law – and encompassesall corporate positions from part-ners and associates down to hum-ble employees. So to minimiseliability risks it is wise to makeenvironmental management anintegral part of modern corporatemanagement. At company level aliability insurance against environ-mental damage and related per-sonal injury is compulsory. In theEU the maximum indemnity limitfor personal injury and materialdamage is €85 million, in theUSA there is no upper limit.

Impact on the European printing industryPollution • Pollution laws inEurope have been harmonisedsince EC directive 96/61/ECIntegrated Pollution Preventionand Control (IPPC Directive) waspassed six years ago. For existingsystems the new law came intoforce in autumn 2007. It alsobrought changes in the licensingprocedures for printing plants.The calculation of VOC thresholdvolumes has been expanded toinclude not just solvents frominks but all solvents (IPA, washes,thinners, from laminators etc).And annual threshold volumeshave now been calculated in addi-

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KBA president and CEO Albrecht Bolza-Schünemann affixing an “Emission tested” seal ofapproval on a hybrid Rapida 105 at Drupa 2000. The two-coater 105’s emissions were wellbelow the permitted thresholds

KBA sheetfed marketing manager Jürgen Veil accepting an “Emission tested” certificate from Albrecht H Glöckle at the second hybrid user forum in April 2005. This certifies that thenew-generation, 18,000sph KBA Rapida 105 complies with the BGDP’s rigorous thresholds and thus also those of the pertinent EC directives

The Berufsgenossenschaft Druck undPapierverarbeitung (BGDP) is the competentauthority on emissions accreditation forGerman press manufacturers such as KBA,and fulfils the same functions as the UK’sHealth & Safety Executive. Its “Emission tested” certificate confirms compliance withindustry thresholds. These are the same as,and sometimes even lower than, the threshold values laid down in EU directives.The BG seal is thus recognised outsideGermany. Nonetheless, KBA has also hadsome of its presses certified by the Europeansafety executive (CEFIC)

KBA established a name for itself someyears ago as a pioneer of greener presstechnology. Evidence of this is the“Emission tested” environmental certifi-cates that have been issued by the Berufs-genossenschaft Druck and Papierverar-beitung (BGDP) for the entire Rapida seriessince Drupa 2000 – including the latesthigh-speed generation, hybrid and UV ver-sions and large-format presses. The emis-sion thresholds tested by the BGDP (theGerman equivalent of the H&SE in the UKand OSHA in the US) are shown in the tablebelow. The forerunner of the 18,000sphRapida 105 was the first sheetfed offsetpress on the world market to be awardedthis BGDP certificate, whereby the dampen-ing unit, with reduced alcohol emissions,played a major role. The dampeners fittedon commercial web offset presses have alsobeen modified to allow low-alcohol or alco-hol-free printing. There are large numbersof KBA sheetfed and web customers print-ing with reduced or no alcohol. Naturally,the surface of the rollers and cylinders mustalso be compatible with vegetable-basedcleaning agents.KBA’s commitment to environmentallyfriendly waterless offset is unique in themarketplace. The presses concerned havealso passed the BGDP accreditation proce-dure with flying colours. This applies notonly to keyless sheetfed technology (Genius52UV, 74 Karat, Rapida 74G) and newspapertechnology (Cortina) but also to presseswith conventional temperature-controlledinking units (Rapida 74 to 162, 46 Karat).Environmental regulations are particularlystrict in Scandinavia. Printing plants andpresses there must carry more certificatesthan anywhere else. As a consequence, theproportion of waterless or alcohol-freeRapidas is exceptionally high.Although safety regulations stipulate thatradiation protection must be in place atthe end-of-press dryer to prevent UV emis-sions, there are still a lot of older presses in

KBA pioneers green printingKBA pioneers green printing

Emission source Agent, process ThresholdFount solution in dampeners and water circuits VOC isopropanol 500 mg/m3

Inks, coatings and cleaning agents in inking and coating units VOCs with hydrocarbons 500 mg/m3

Inks on high-speed inking rollers ink aerosols (ink mist) under discussionUV lamps in dryers ozone 0.2 mg/m3

UV lamps in dryers UV radiation 0 (as per prEN 1010-2)Powder sprayer in the delivery powder 6 mg/m3 (1.5 mg/m3 under discussion)Entire press line noise 84 dB(A)

operation where no protection is providedfor personnel against carcinogenic UV radi-ation. KBA has long since made opaqueradiation screens a standard feature of all

its UV and hybrid presses. An extractor isused to remove the ozone (O3) that is pro-duced when shortwave UV photons collidewith the oxygen (O2) in the air. As an

optional extra for the delivery KBA alsooffers an ACS air cleaning system to extractthe powder, paper dust and any residualozone that may be carried on the sheet sur-

Emissions tested at offset presses for BGDP accreditation

tion to the hourly consumptionlimits. If emissions exceed 200tonnes per year then the emittermust apply for a licence. Heatsetpresses are no longer classified bytheir threshold volumes, andmust now be certified in thesame way as flexo and gravurepresses under the VOC SolventsDirective on the limitation ofemissions of volatile organic com-pounds due to the use of organicsolvents in certain activities andinstallations (1999/13/EC, seetable on page 3). Solvent audits

(see schematic on page 3) andreduction schedules must bedrawn up for such presses. Thesame applies to ink and coatingmanufacturers’ production andfilling lines.

Cross-industry threshold listsare adjusted every year and ex-panded to include new hazardoussubstances. Printing plants mustalso study these values for maxi-mum workplace and ambient con-centrations. Selected thresholdsare shown in the table on page 6.No outdated technologies • In accor-

dance with the IPPC Directive,licensing procedures in EU mem-ber states specify that installa-tions must be on a par with thebest available techniques (BAT), ieones that have a smaller environ-mental impact or entail greenerprocesses than earlier technolo-gies. The licensing institutionsmust comply with BAT referencedocuments (BREF) issued by theInstitute for Prospective Techno-logical Studies (IPTS) in Seville.The reference documents aredrawn up by experts from public

authorities and from industry,including KBA. Waterless offset isan exception to the BAT rule.Although it should, in all honesty,be considered a BAT for offsetprinting, wet offset presses arestill assessed with no referenceto fount-free technology. The BATused as a benchmark in wet off-set – beside the technology toremain below emission thresh-olds – is the potential for alcoholreduction.Handling waste • In the printingand packaging industry, the non-

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A lot of paper dust and powder is deposited on grippers and lamphousings at the end-of-press dryer and sheet delivery (above). To protect press operators from exposure to dust and powder and to prevent contamination of the console and pressroom equipment KBAcan install an Air Cleaning System (ACS, below) in the delivery of itsRapida presses. On UV and hybrid presses ACS also extracts ozoneresidue

Its waterless coldset offset technology, which dispenses with fountsolution and thus with alcohol, is not the only reason why the KBACortina compact newspaper press is environmentally friendly. Its dedicated drives eliminate the need for lubricating oil in the printingunits (above), while keyless inking units eliminate ink mist (below)

Sandler in Marbach an der Donau (Austria) inaugurated the world’s first environmentallyaccredited twelve-unit sheetfed press, a Rapida 105, in 2002. Eight printing units are connected to Technotrans water-circulating systems (one for four units) that allow alcohol-freeCMYK perfecting. Each of the two remaining pairs of printing units is connected to an additional circulating system that allows metallic inks to be printed with the necessary alcohol content of 3% or less. The vegetable-based inks are pumped automatically to the ink ducts either from a vat (process colours, coatings) or from cartridges (special colours)

David Gask, managing director of the Polar Print Group, Leicester, invested a cool£3 million in a project seeking to make twoKBA Rapida 105 presses alcohol free and carbon-neutral

face or on the air disturbed by the grippers.More and more environmentally focusedprinters are acknowledging KBA’s pole posi-tion in green press technology. One currentexample is the UK’s Polar Print Group basedin Leicester, which has teamed up with KBAto forge a broad coalition of like-mindedmanufacturers in the paper, ink and con-sumables industries. Polar invested in twoKBA Rapida 105 presses to implement itstrademarked “Printing Responsibility”project, a corporate philosophy promotingcompliance with ethical printing standardsthrough sustainable emissions reductionand carbon-neutral production. After con-ducting detailed comparative studies ofother makes of press it went for a six-colourhybrid version, which was commissioned inNovember 2007, and a ten-colour perfector,

which will be installed in 2008. Since Polarhas ISO 12647-2 accreditation, the Rapida105’s quality assurance systems wereanother reason for choosing KBA.When thefirst press was installed, its CO2 emissionswere calculated by an independent expertand will be offset by emissions trading.Both presses are equipped for alcohol-freeproduction. Polar’s objective is to increaseturnover from £4.5m to around £6.5mwithout increasing its carbon footprint.ThePrinting Responsibility project is supportedby environmental organisations such asGreenpeace, Friends of the Earth and ComicRelief. Polar is considered a leading light inthe UK print media industry on issues relat-ing to conservation. In addition to ISO12647-2 it boasts ISO 14001, ForestStewardship Council (FSC) and OHSAS18001 (health and work safety) accredita-tion.

woven materials and cleaningrags used in the printing process,and all returnable containers, areclassic examples of cleanable,reusable waste. Paper and pack-aging waste, however, can onlybe recycled, and it is mainlypaper that is returned to the orig-inal materials cycle; most syn-thetic and composite waste istaken to incinerators. So packag-ing printers have an ethical dutyto develop recyclable, non-pollut-ing, combustible or biodegrad-able packaging. On top of this,

packaging should fulfil its pur-pose with the minimum possibleinput of material. In the EU,national measures relating to themanagement of packaging andpackaging waste have been har-monised since 1998 in accor-dance with directive 94/62/EC.Handling dangerous substances •Since June 2007, laws governingchemicals have also been har-monised throughout the EU inaccordance with regulation1907/2006/EC on the Registra-tion, Evaluation, Authorisation

and Restriction of Chemicals(REACH). It encompasses accessto databases on dangerous sub-stances and goods such as poi-sons, flammable and explosiveliquids, softeners, heavy metalsetc, and safety data sheets relat-ing to their transport, storage,processing and disposal. Whiledangerous substances are stillclassified, packaged and labelledin accordance with directive67/548/EEC, under the newchemicals law the burden ofproof is reversed and now corre-

sponds more closely to theAmerican model. It is no longerthe injured party but the emitter,in this case the printing plant,that must provide complete docu-mentation on the composition ofprinted matter or packaging.REACH also applies to dangeroussubstances in printed productsmanufactured outside the EU, egin China, but destined for theEuropean market. In recent yearsthis has resulted in toys and chil-dren’s books being recalled forsafety reasons. It goes without

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Key ISO 14000 norms relating to environmental management and contamination controlISO Type Content14001 Specification Environmental management systems – Specification with guidance for use14004 Directive Environmental management systems – General guidelines on principles, systems and supporting techniques14010 (EN)* Directive Guidelines for environmental auditing – General principles14011 (EN)* Directive Guidelines for environmental auditing – Audit procedures14012 (EN)* Directive Qualification criteria for environmental auditors14024 (EN) Specification Environmental labels and declarations14031 (EN) Directive Environmental management – Environmental performance evaluation14040 (EN) Specification Environmental management – Life cycle assessment – Principles and framework14041 (EN) Specification Environmental management – Life cycle assessment – Goal and scope definition and inventory analysis*superseded by 19011 Guidelines for quality and environmental management systems auditing

Some international threshold values in the printing industryMaterial Max. airborne concentrationAcetone (in cleaning agents) 20 ml/m3 = 83 mg/m3

Aluminium oxide (on roughened offset plates) 1.5 mg/m3

Benzene (in solvents and cleaning agents) 1 mg/m3 (2.5 g/h)Butyl acetate (solvent in certain inkjet inks) 5 ml/m3 (USA), 20 ml/m3 (EU)Isopropyl alcohol (in offset fount solution) 200 ml/m3 = 500 mg/m3

Carbon atoms (in exhaust fumes and air)- afterburning 20 mg/m3

- adsorption cleaning 50 mg/m3

- biofiltration 90 mg/m3

Copper (in electrolytic vats) 0.1 mg/m3

Methylene diphenyl diisocyanate (in PUR adhesives) 0.05 mg/m3

Ozone (in UV and corona devices) 120 mg/m3 (up to 8 hours)Dust (paper/fillers, powder)*

- alveolar particulate matter< 10 µm 3 mg/m3

- respirable dust > 10 µm 10 mg/m3

- paper particulate matter < 0.5 mm (in coldset) 30 g/m3 (lower explosion threshold)- dust deposits on surfaces 350 mg/m2

Toluene solvent (in gravure inks) 190 ml/m3 = 50 mg/m3

Xylene solvent (in gravure inks and coatings) 440 ml/m3

* Manufacturers’ voluntary controls: the minimum particle size of fine printing powder may deviate from the mean (80% frequency) by no more than 20 µm

Noise exposure limits as laid down in EU directive 2003/10/ECDaily level Peak sound pressure Noise controlsfrom 80 dB(A) to 135 dB(C) voluntary hearing protection and hearing testfrom 85 dB(A) to 137 dB(C) obligatory labelling, obligatory hearing protection,

right to hearing testfrom 87 dB(A) to over 137 dB(C) plus machine encapsulation

saying that environmentallyfriendly production encompassesthe substitution of hazardoussubstances with harmless ones.

Product accountabilityIntegrated product policy • Ethicalproduction policies are sum-marised in a number of publica-tions, among them the EU’sgreen book on Integrated ProductPolicy (IPP) 2001, which advo-cates making manufacturersaccountable for the entire lifecycle of their products. This is ofparticular relevance for packagingprinters, whose products must beenvironmentally friendly, reus-able or recyclable. KBA acknowl-edges a duty to develop pressesthat are manufactured in environ-mentally friendly conditions andto guarantee that their emissionlevels will not exceed the origi-nal, certified levels for the dura-tion of their service life. KBA hasestablished a formidable standingas a pioneer of waterless and key-less offset technology, enablingusers to minimise waste levels byeliminating water and alcoholsubstitutes.Choosing green materials • TheProduct Design for Environment(DfE) initiative has a similarthrust, though its main focus is topromote the use of environmen-tally friendly materials, includingprinted products and packaging.Biodegradability and standard-ised, reusable composite materi-als (eg Tetrapak) are two of theissues treated. KBA supports DfEby eliminating pollutants. Thedirect cylinder drives in theCortina and Commander CT, forexample, allow the printing unitsto be operated with no lubricat-ing oil. In the print media indus-try, Product Design for Recycling(DfR) refers to de-inkability, say,or 100% recyclability. DfE andDfR are a must for any eco-man-agement system.

Standards and certificatesSelected modelsAccountability • Nowadays compa-nies with environmental ambi-tions are expected to seize theinitiative, and in view of anemerging demand among cus-tomers for greener products, thishas become a key image and dif-ferentiation factor. More specifi-

cally it entails adopting an envi-ronmental management systemand/or providing proof of sustain-able technologies and materialsprocurement. An added bonus isthat implementing an environ-mental management system willreveal cost-saving potential, socertification is always well worththe input.ISO 14000 • The ISO 14000 seriesof international standards (seetable at the top of this page) regu-lates the implementation of anenvironmental management sys-tem within an enterprise. Most ofthe norms in this series are basedon an EU norm (EN) and aretherefore found in many nationalnorms. The most important stepsare described in ISO 14001, forwhich companies can obtainaccreditation. The focus of an en-vironmental management system

is the environment programmethat an enterprise is obliged toimplement. ISO 14040 describeshow to draw up an eco-audit.EMAS • The Eco Management andAudit Scheme (EMAS) was initial-ly established by EuropeanRegulation 1836/93, though thishas since been superseded byCouncil Regulation 761/01. It is avoluntary initiative designed toimprove companies’ environmen-tal performance. Among the EUmember states EMAS is as wide-spread as ISO 14000, but goesstill further by requiring partici-pating organisations to publishregular statements on their envi-ronmental performance. Thesestatement must include goals andprocedures relating to environ-mental policy, an eco-audit (con-sumption of resources and mate-rials, with the resulting emis-

sions) and the environmentalmanagement system. The state-ments must be verified by anindependent expert before thecompany can be registered by thecompetent national organisationas having a valid environmentalmanagement system.Sustainability report • This is goodfor marketing purposes and thecorporate image, and is issued bymany companies alongside theirbusiness reports. Among printmedia enterprises, the public lim-ited company (UK) or stock cor-poration (US) is a common formfor globally active groups andmedia houses, and for smalleroperations, particularly inSwitzerland. But regardless of itslisting, legal form or size, anyprint provider can publish itsenvironmental programme on theinternet. A sustainability report isonly compulsory if the companyis listed in one of the Dow JonesSustainability Indices (DJSI World,DJSI STOXX Europe). In autumn2007 the Austrian paper andpackaging producer Mondi waslisted in both indices following amanagement assessment that willbe repeated every year.

The sustainability reportevolved from earlier annual envi-ronmental reports and the three-yearly location-specific environ-mental statement, but includesmore of what are known as G3indicator categories in accor-dance with Global ReportingInitiative (GRI) guidelines. Along-side environmental performance(30 points) the main indicatorsare governance, commitments,engagement (17), working prac-tices and employment (14),report parameters (13), corporateprofile (10) and product responsi-bility (9).Sustainable Green Printing Partnership •This initiative was established in

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Materials flow at a full-service print provider. A detailed schematic should be an integral part of the materials flow management conceptembedded in every corporate environmental management system and furnish the basis for calculating job-specific CO2 emissions

In Sankey diagrams depicting a materials flow management system, the volume and cost are visualised by the thickness of the arrow Source: Synergetic Freiburg (Meyer)

September 2007 in the USA bythe Printing Industries of Ameri-ca/Graphic Arts Technical Foun-dation (PIA/GATF), the SpecialtyGraphic Imaging Association (SGIA)and the Flexographic TechnicalAssociation (FTA). More than 90%of its member companies are per-suaded that, in future, print cus-tomers will go for environmental-ly printed products.Sustainable forest stewardship • Twoinitiatives have evolved for certi-fying the wood-processing indus-try: the Programme for Endorse-ment of Forest CertificationSchemes (PEFC) and the ForestStewardship Council (FSC). Bothare international, non-profitENGOs (environmental non-gov-ernmental organisations) found-ed to support environmentallyappropriate, socially beneficialand economically viable manage-ment of the world’s foreststhrough independent forest man-agement certification and market-place labelling of certified forestproducts. This encompassesreforestation, the promotion ofbiodiversity and sustainability,and the protection of forest habi-tats. Both ENGOs offer chain-of-custody certification from theforest to the sawmill to the retail-er, which includes paper millsand printing plants.

PEFC and FSC have beenrepeatedly accused by environ-mental activists of pandering tothe logging industry, but re-nouncing any form of loggingwould merely drive up demandfor non-renewable resources anddestroy jobs in structurally weakregions. An alternative to wood-based papermaking is the focusof research by Japanese printermanufacturer Oki and DalianPolytechnic in China. Before theend of the year they are aiming tolaunch on the market office print-ing paper whose fibres arederived from annual crops, nottrees. Such projects notwith-standing, forest management islikely to retain its present signifi-cance in the long term.Paper profiles • Even without PEFCor FSC certification, many paper-makers have adopted greatertransparency and responsibility inthe chain of custody. Since theyusually have ISO 14000 accredi-tation, they are already docu-

menting recycling percentages,eco-audits, resource cycles, vol-ume-for-volume grammage reduc-tions and greener, more socialstandards for paper productionand utilisation. At the initiative ofnine paper manufacturers anddealers (Holmen, Klippan, M-real,Myllykoski, Norske Skog, SappiFine Paper Europe, Stora Enso,Trebruk and UPM-Kymmene),each type of paper has been givena profile revealing details of thesupply chain, environmental man-agement and the chemicals used.Advice and promotion • The intro-duction and certification of envi-ronmental management systemshas been accompanied by indus-try bodies and authorities whichare fully conversant with nationaland EU development pro-grammes. There are also a num-ber of consultancies specialisingin the analysis, organisation andpermanent computer-aided evalu-ation of materials flow manage-ment, order-specific CO2 emis-sions and the like. These includeCP California and CP UK.

Conservation toolsEnvironmental controlling: a signatureissue• Conservation brings re-wards as well as risks. Far-sightedenvironmental protection cansafeguard the long-term future ofa company and its location.Furthermore, adopting an envi-ronmental management systemcan reveal wasteful consumptionof materials and resources andthus potential for process optimi-sation. Conservation becomes anintegral part of corporate philoso-phy because management mustdefine its environmental policy inwriting as a basis for environmen-tal management. This in turn cre-ates the need for staff motivationand training in environmentalissues. Monitoring the optimisedmaterials flow (for example withthe aid of current VOC audits),implementing concrete environ-mental projects and promotingstaff discipline in environmentalissues represent new manage-ment tools for company heads.Successful implementation, whichshould undoubtedly be certified,

can make environmental engage-ment a highly effective marketinginstrument.Environmental management systems •The purpose and responsibilitiesof an environmental managementsystem are defined in the compa-ny’s environmental policy. Thepractical section begins with acomprehensive analysis of all per-tinent processes (cf materialsflow management below) and abreakdown of environmentalrisks. From this it is possible toformulate an environmental pro-gramme that defines the compa-ny’s environmental performance.This performance must not onlybe maintained consistently butcontinually enhanced throughcareful planning and control. Spe-cific instruments include recy-cling instead of disposal, the useof green consumables (eg inksand washes) instead of fossil-based ones, and process optimisa-tion. Keeping a record of actiontaken and targets achieved allowsthe company to track progress viaregular eco-audits.

An environmental programmeincorporates all the directives,laws and regulations that are per-tinent to environmental account-ability in the relevant industry. Atthe same time staff competencesshould be defined with regard tothe compliance or optimisation ofspecific processes. A commend-able consequence is the integra-tion of environmental parametersin the management informationsystem (MIS, dedicated sofware),for example to show calculatedconsumption and times in a job-specific VOC audit.

Environmental resources: energy, water, air, mineral and vegetable oils, wood, colorants, metalsMaterials: substrates/packaging, printing formes, rubber blankets, printing inks, coatings/foils/filmsAuxiliaries: chemicals, washes, lubricating oils, materials/auxiliaries packagingProduction and communications technology: buildings, computers, networks, equipment, machinery, vehicles

Production: pre-press (printing forme), printing/inline coating (printed sheet, cut-off),finishing (print, packaging), distribution (carrier, personal collection)

By-products: paper waste, ink/coatings, foil, film, plates, effluent, exhaust airEmissions: VOCs, CO2, fumes, waste heat, noise, vibration

Recycling: waste paper/metal processing, effluent treatment,catalytic exhaust air purification, heat recovery from afterburning

Disposal: landfill, incineration

Dresdener Ring 6061130 Nidderau, GermanyTel: (+49) (0) 6187 3153 E-mail: dieter.kleeberg@t-online.de

Supplement to KBA Report No. 32(English edition)

Translated by Christina Degens-Kupp

Koenig & Bauer AktiengesellschaftWürzburg Facility97010 Würzburg, GermanyTel: (+49) 931 909-0Fax: (+49) 931 909-4101Web: www.kba-print.comE-mail: kba-wuerzburg@kba-print.de

Frankenthal Facility67225 Frankenthal, GermanyTel: (+49) 6233 873-0Fax: (+49) 6233 873-3222Web: www.kba-print.comE-mail: kba-frankenthal@kba-print.de

Radebeul Facility near Dresden01439 Radebeul, GermanyTel: (+49) 351 833-0Fax: (+49) 351 833-1001Web: www.kba-print.comE-mail: office@kba-print.de

KBA-Metronic AGBenzstrasse 1197209 Veitshöchheim, GermanyTel: (+49) 931 9085-0Fax: (+49) 931 9085-100Web: www.kba-metronic.comE-mail: info@kba-metronic.com

8 Print to Web

Registered trademarks, copyrighted and patented products are not specified as such in the abovefeature. This does not mean that they are, or may be treated as, public domain. The figuresquoted date from November 2007. Errors and omissions excepted.This publication contains illustrations from KBA, Technotrans, Berufsgenossenschaft Druck undPapierverarbeitung and Synergetic Freiburg.

Selected consulting, promoting and certifying institutionsCountry Organisation InternetDenmark Grafisk Arbejdsgiverforening www.ga.dkFrance FICG www.ficg.fr/site/Italy AssoGrafici www.assografici.itNetherlands KVGO www.kvgo.nlSpain FEIGRAF www.feigraf.esSweden Grafiska Företagens Förbund www.grafiska.seUK British Printing Industries Federation www.bpif.org.ukUSA GATF, PIA,TAGA www.gain.netUSA FFTA www.flexography.orgUSA Gravure Association of America www.gaa.orgUSA Printers’ National Environmental Assistance Center www.pneac.orgUSA U.S. Environmental Protection Agency www.epa.govEC European Commission, Environment ec.europa.eu/environment/index_en.htmEC Environmental Technologies Action Plan (ETAP) ec.europa.eu/environment/etap/index_en.htmEurope European Flexographic Technical Association www.efta.co.ukEurope European Rotogravure Association www.era.euWorldwide INCA-FIEJ Research Association www.ifra.comWorldwide Intergraf www.intergraf.orgWorldwide PIRA International www.pira.co.ukWorldwide TAPPI www.tappi.orgWorldwide Waterless Printing Association www.waterless.org

Materials flow management • Costflow calculations show that thematerials and energy consumedin a printing plant account for abigger proportion of costs thanlabour. In addition to waste-reducing technologies which canonly be acquired through capitalinvestment, it is necessary toexploit any potential for furthersavings. This includes a betterutilisation of paper formats, areduction in trim waste and theavoidance of all types of waste ingeneral, for example throughimproved facility managementand building automation in bothproduction and administration.This is because the much-cited“dripping tap” often takes theform of faulty, inefficient or non-existent air-conditioning, anabsence of heat recovery sys-tems, and decentralised or leakycompressed-air supply systems.Plants with their own deliverydepartment often waste time andmoney through inefficient routeplanning.Environmental purchasing • This toolextends environmental manage-ment to materials procurement.For printing plants, this meansbuying renewable resources inthe form of vegetable-basedpaper, inks and washes.Emissions trading • The papermak-ing and printing industries aremajor emitters of greenhouse

gases, which politicians tend toequate with the biggest emission,CO2. So proof of an independentcarbon audit – in addition to aneco-audit – can be an effectivemarketing tool when bidding forcontracts.

Materials flow managementsoftware can be used to carry outthis audit and thus quantify acompany’s carbon footprint,which along with labour andtransport includes the consump-tion of natural resources, con-sumables and additives. Emis-sions from one location can beneutralised by a correspondingreduction in emissions fromanother anywhere else in theworld. The system is co-ordinat-ed via emission trading permitsissued under officially recognisedinternational climate protectionschemes. Critics describe the cer-tificates issued as “letters of in-dulgence for a clear conscience”,supporters argue that in the caseof a global phenomenon it is im-material where protective actionis taken, the main thing is that itis financed.

The cost of these emissiontrading certificates is usuallypassed on to consumers, butshould, in principle, have a negli-gible impact on the price of print-ed products. In return customerscan advertise the fact that printproduction was carbon-neutral,

and have a certificate issued bythe printing plant to prove it.Environmentally conscious cus-tomers can thus extend theircommitment to embrace printbuying, and this may play a majorrole in their future choice ofprint provider.Low-emission technologies • But forthe environment it is best toavoid emissions in the first place,by using alcohol substitutes,waterless offset or other low-VOC technologies, eco-accredit-ed presses and direct drives suchas KBA’s DriveTronic system,which are not only oil-free butalso reduce waste.Work safety and health protection •Conservation is a contributiontowards a cleaner, safer workenvironment. It minimises therisk of occupational diseases andpromotes a more positive workethic among employees.

OpportunitiesTo sum up, these are the opportu-nities afforded by certified envi-ronmental management andmaterials flow scenarios.•From the business perspective,detecting synergy potential whileimplementing an environmentalmanagement system is alwaysworth the time and effort.•All internal and inter-companyprocesses are scrutinised and canbe optimised.

•Resources and materials areutilised more efficiently. Wastereduction and prevention canlead to substantial cost savings.•Life cycles and the timing oftechnology upgrades are exam-ined more thoroughly.•Environmental discipline is alsostaff discipline. Environmentalcontrolling becomes a manage-ment tool.•Print providers can differentiatethemselves via their environmen-tal programme, eco-accreditedproduction, sustainable paperproducts, carbon-neutral printingetc, which can be an effectivemarketing tool.•Print customers can burnishtheir own environmental creden-tials by specifying greener prod-ucts, which influences theirchoice of print provider.Dieter Kleeberg