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Sustainable Print Media

IP - Erasmus

MediaPro – Athens 8 June 2010

Professor Johan Stenberg, KTH Media, Sweden

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Project work1) You are in charge of planning a new production facility for newspaper printing. Describe how a new plant and its production process should be designed in order to obtain a sustainable production and distribution process. Consider both the building design and the design of the production and distribution process! How will you communicate your environmental impact when the new facility is running?

2) You are in charge of planning a refurbishment of an old production facility for newspaper printing. The original plant and its equipment was design 20 years ago and no special environmental care was taken at that time. Describe how you can change the existing plant and its production process in order to obtain a more sustainable production process. Consider both the building and the design of the production process! How will you communicate your environmental impact when the refurbished plant is running?

3) You are in charge of planning an equipment upgrade project at a medium-sized digital printing company. The idea is to make sustainability one of the key selection criteria (among costs, quality, productivity and service) when choosing digital printing equipment (colour and monochrome electrophotographic presses and wide-format inkjet printers) and related finishing equipment. Which issues of sustainability would you like to include in the selection criteria, which evidence would you require from the vendors/manufacturers, and how would you quantify the different criteria and compare the alternatives?

4) You are in charge of planning and running a sustainability management system at the above mentioned digital printing plant. How would you make sure that the operation of the plant is as sustainable as possible? Consider the purchase of materials, the use of resources (energy, water), waste output, sorting and recycling, emissions to air and water, the recyclability of products etc. Think also about training of staff and information to customers!

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Agenda

My background

The Media Sector – the Swedish situation

Newspaper printing from a process perspective

Sustainable Print Media

Summary

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My background Master of Science in Media Technology 1991

KTH Media Technology

Doctor of Technology - Media Technology 1997KTH Media Technology

Project Manager 1997-1998Östgöta Correspondenten – A Swedish Regional Newspaper Group

Managing Director/Consultant Manager 1999-2007MWM Media Workflow Management AB

Technical Director 2007- Bold Printing Group AB

Visiting Professor 2009-KTH Media Technology

Hobbies: My family, kayaking, skiing, music, film and artMarried to Cecilia and the father of three children 16-20 years old

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The job at Bold Printing Group AB

Technical Director

– Responsible for technology, investments and projects

– Production equipment, infrastructure and IT

– Development of processes and products

Second largest newspaper printing group in Sweden

– Revenue 130 million Euro, 130 000 tons of newsprint, 500 persons

– Several printing plants across the country

Annual investment level (average)

– Approximately 8% of the total revenue is invested every year

– 8% of 130 million Euro approx 10 million Euro/yr

– New investments approx 4,5% of the total revenue

– Refurbishment approx 3,5% of the total revenue

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The job at KTH Media Technology

Visiting professor 40%

Project Manager Media & Sustainability

Responsible for the masters programme in Media Technology

Supervision and examination of Diploma work etc

Lectures and seminars

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Print Media – a part of the media landscape

The Swedish Media Sector 2008: Revenue 6 500 million Euro

Source: Swedish Media Publishers’ Association

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Swedish Media Share of Ad Spend, 2008

Source: IRM, Institute of Ad and Media Statistics, Sweden

35% Dailies.

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Source: IRM, Institute of Ad and Media Statistics, Sweden

Swedish Media Share of Ad Spend, 2000-2008

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The Newspaper Printing Process

Heavy industrial production

– Often focus on just-in-time production

– Large share of material costs – approx 50%

– Large investments 10-20 years life-span

– High utilisation of capital intensive resources a must in todays media competition!

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Sustainable Print Media

- Electricity- Heating- Cooling- Water

- Equipment and systems- Newsprint (Recycled + virgin fibres)- Ink (oilbased)- Al-Plates- Other consumables

- Rest ink + water- Used Al-plates- Newsprint waste- Used equipment (3-20 years)

- PDF:s (pages)- Addresses- Externally printed supplements

- Newspapers- Free papers- Supplements- Direct mail products

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Materialhantering

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Mailroom: Ferag/IDAB Wamac

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Case study

What can a newspaper printing plant do to obtain a more sustainable print media

production?

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Factors to consider• Reduction of energy consumption?

- The Building

- Equipment used

- Losses related to infrastructure eg compressed air, cooling, heating,…

• Reduction of waste/material consumption?

- Start-up waste

- Running waste in the printing press

- Mailroom waste and overprinting

- Processes development in order to hit target volumes without to large margins (reliable copy counting)

• Reduced transportations?

- Locally produced newsprint and ink

- Use of ink tanks

- Reduced waste

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Annual energy consumptionPlant no Building area

(sqm)Annual

newsprint consumption

(tonnes)

Annual energy

consumption(GWh)

1 5 000 20 000 4

2 80 000 70 000 24

3 15 000 30 000 8

• Three plants with similar production, climate conditions, and equipment but completely different building sizes

- Production and heating/cooling/ventilation/climatization of the buildings are the major internal energy drivers

- Make a rough model of the energy consumption for the production and the buildings based on the figuresabove!

- What is rougly the energy cost per tonne newsprint produced and sqm building/yr if 1kWh costs 0,10 Euro?

- Discuss and calculate in groups during 10 minutes Results and Conclusions?

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Plant 2: 80 000 sqm used by the printing company

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Key figures 2009

Plant 1 Plant 2 Plant 3

In production since 2002 1993 1994

No of folders 1 4 2

Building size in use (sqm)

5 000 80 000 15 000

Employees 57 335 138

Energy consumption (GWh)

4 24 8

Newsprint consumption (tonnes)

20 000 70 000 30 000

Revenue (million Euro) 18,1 72,8 30,4

Material costs (million Euro)

-9,9 -34,6 -14,5

Profitability% 9,4% Neg 4,3%

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Compact living efficient use of the energy!

The energy consumption is heavyly influenced by the size of the building

– Heating, cooling, climatization (50-55% humidity)– The energy consumption normally peaks in August when the production

volumes are low!

The present 80 000 sqm in plant 2 is not needed. – The plant was planned during the late 1980’s at a time with strong

finances and with no special focus on sustainablity or energy savings

The future need is 24 000 sqm (compared to plant 3: 12 000 sqm and plant 1: 5 000 sqm) – no change in production volumes!

The remaining 56 000 sqm will be used by other businesses!

How can more than 2/3 of the building area be reduced? – Investment in more efficient production equipment– Less staff is needed– A changed mindset with focus on cost efficiency and sustainability

The reduced space and costs for the building will strongly contribute to reach profitability!

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Material efficiency• The material stands for roughly 50% of the costs in a

Swedish newpaper printing plant and newsprint is the major material

- Waste means extra resource consumption!

The newsprint itself

Electricity consumed when the waste is printed

Ink on printed waste

Loss of production time

Extra transportations to handle the waste

- The newsprint utilisation varies from normally from 85-95% and is influenced by

Circulation

Equipment

Knowledge & skills

Process stability

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How is the Newsprint Utilised/job? Waste type Quantity old

plantQuantity new

new plant

Brown waste 10 kg/reel 10 kg/reel

Stripping waste 1,5 kg/reel 1,5 kg/reel

Core waste 8 kg/reel 8 kg/reel

Startup waste 3 000 copies/production

400 copies/production

Running waste 1 290copies/production

500copies/production

Edition change waste

800copies/production

200copies/production

Mailroom waste 860copies/production

500copies/production

• Newsprint utilisation: Ordered newspapers (kgs) divided by the total newsprint consumption (kgs)

• Basics: 86 000 ordered copies/job, 1 edition change/job,1 500 kgs/reel, product weight 120 gram/copy

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Newsprint Utilisation

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Material efficiency: Ink and electricity• How much will the ink consumption be reduced in the new

plant based on the improved newsprint utilisation?

- The old plant uses 70 000 tonnes newsprint and 1 380 tonnes ink per year

• How much will the consumption of electricity be reduced in the new plant based on the improved newsprint utilisation?

- The old plant uses 70 000 tonnes newsprint

- Assume that every ton of newsprint requires 150 kWh of electricity for the production

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Newsprint and Transportations• Many mills are developing towards green processes

(Swedish Holmen amoung others)

• Newsprint transportations

- In Sweden there are several newsprint mills across the country

- Most transports are carried out by 24 m trucks incl trailers

- Each transport can carry 22 reels (160 cm wide reels, diameter 125 cm, 1 500 kg)

- Some plants can handle newsprint as railway cargo

- Improved newsprint utilisation also means less transporations

- The distance to the mill and the transporation method must be considered

• Ink is transported on trucks - often with 5 ton tanks or in small containers

- Ink tanks means less transports

- A fixed tank in the plant i normally contains 5-15 tonnes while a container often contains 1 ton

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Summary• The printing plant building is a major energy consumer

• Develop the building and its technology in order to reduce the need for electricity (climatization, ventilation and heating)

• Consider how your energy can be re-used in several steps!

• If the printing press is cooled, use that system to heat the plant etc

• The paper is the major raw material used – use it as efficient as possible

• Monitor your paper consumption and identify how the waste can be reduced

• New highly automated printing technology means less waste

• How can the need for external transports be reduced

• Choose a mill closer to your plant if you can afford it

• Put pressure on your paper supplier to developa sustainable process