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Environmental protection at Heidelberg PDF

16 Pages·2004·0.32 MB·English
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Printingand the Environment N°11 Environmental protection at Heidelberg – production, products, advice and knowledge transfer Contents 4 Preface 5 Guideline for environmental protection, occupational safety and product safety 6 Environmental protection at Heidelberg 8 Speedmaster Star System 10 Product development highlights 12 Environmentally sound production 13 Environmental labels for Speedmaster presses 14 Knowledge transfer 4 Printing and the Environment Preface Heidelberg is committed to sustainability • What benefits does the customer get from this? Bernhard Schreier, Heidelberg CEO Against the backdrop of its sustainability policy, Heidelberg is committed to continually improving its environmental protection activities in its product development facilities and various sites. Our “Printing and the Environment” series of brochures aims to show how our customers benefit when Heidelberg makes product- and process-related advances in the field of environmental protection. We want to describe how our activities help our customers to become more environmentally compatible and forward-looking in their production environment, the “printshop.” The demands that our customers have to satisfy are increasing on every front. Not only do they have to supply high quality work, they are also expected to be cost-effective and deliver punctually. At the same time they are also having to respond to their customers increasing demands for environmentally compatible products and processes. In optimizing its products and processes relating to every aspect of the press, Heidelberg is also making concerted efforts to significantly improve environmental and health protection. The use of consumables in presses is significantly reduced. This in turn reduces operating costs. Consequently, ecological and financial benefits go hand in hand. Integrated environmental protection at Heidelberg also includes efficient environmental management at its various sites and a thorough examination of the whole life-cycle when developing products. This also involves paying close attention to regulatory developments and keeping a keen eye on our customers’ future requirements. Heidelberg sells its products globally. This means that our presses need to meet a consistently high standard of quality, product safety and environmental compatibility across the world’s markets. The following guideline provide a basis for this. They demonstrate how environmental protection, occupational safety and product safety are tightly intermeshed, both at production sites and in our product development work. Guideline Printing and the Environment 5 Guideline for environmental protection, occupational safety and product safety. 1. Our activities are based on the model of sustainable development and the principle of continual improvement. With regard to our products, we are therefore committed to identifying and implementing safely operable, cost-effective, environmentally compatible and socially responsible solutions over their entire life cycle, from manufacture to disposal. Environmental aspects and product safety are an integral part of our systematic product development process. We shall strive to actively involve our suppliers and business partners in our efforts to achieve this aim. 2. We implement official requirements, laws and regulations at all Heidelberg sites. Our products meet all the legal requirements laid down in the markets where we are active. Internally, we use the best available technology for occupational safety and environmental protection when putting new invest- ment into our sites and product development. When implementing all these measures, we go above and beyond the legal requirements insofar as this is expedient and cost-effective. 3. Our aim is to safeguard our employees against health hazards and to reduce the potential for impairment of the environment at and around our sites. We are committed to actively preventing accidents and emergency situations at all our sites. 4. We are continually improving occupational safety and environmental protec- tion as well as the environmental compatibility and safety of our products. Wherever feasible, we are committed to conserving resources and to taking advantage of opportunities for recycling and minimizing waste production. 5. In conjunction with employees, management develops and agrees on the required objectives regarding occupational safety and environmental protec- tion and regularly reviews the implementation of the measures resulting from them. 6. We need responsibly minded employees at all levels who actively help to put our occupational safety and environmental protection principles into practice. Through appropriate information and training, we help employees to play an active role in occupational safety and environmental protection and to implement corresponding measures. 7. We shall pursue an open dialog and strive to actively share information with the responsible authorities, shareholders, the public and everyone else involved in the life cycle of our products. We are committed to providing support to our customers on the environmentally compatible and safe oper- ation of Heidelberg products through training and information. Heidelberg, March 2004 Bernhard Schreier, Heidelberg CEO 6 Printing and the Environment Environmental protection at Heidelberg Environmental protection at Heidelberg • An ever-present topic at the company, from initial product conception and manufacturing to advising customers. Heidelberg has long been committed Environmentally sound products meet with a hearty response from to protecting the environment. As Product development is a crucial area printshops, and many ideas for early as the start of the 1990s, the com- when it comes to protecting the further optimizing presses come pany formulated its environmental environment. Every Heidelberg press from printshop owners. policy, published its first environ- must not only fulfill high quality Heidelberg has accumulated ex- mental report and produced a journal requirements, be profitable for the tensive knowledge about environ- on product-related environmental customer, and be ergonomic and safe mentally sound product development protection for customers. Heidelberg to operate, it must also be environ- in the course of numerous projects. built up environmental management mentally compatible. For the printer One of the realizations made is that systems in accordance with ISO 14001 this means better air quality in the presses have their greatest impact at almost all its production and devel- printroom, less noise, less waste and on the environment during their opment sites. Since 1999 environ- often reduced costs too, for example utilization phase, i.e. in the print- mental protection is an integral part in disposing of cleaning agents or in room. For example, a Printmaster of product development work. energy consumption. These benefits QM 46 pressweighs just undera ton, but consumes ten times its own weight in ink over ten years. In the same period, three tons of waste is produced and one ton of cleaning p h a se, Development,reutciyliclziantigPornoducts ProductioWenaetergr,ysoil,air, aoeHErgfxes eati hfndmoeterpssl beltiesh efi sure gog sfuf eup rhdrre.otes hAw spesn reer oa nsd vcgaeciinvdunederels aeop tcrpeelsmre aciapanernhna p letbyo rorsiainifnlstsg-. Integrated n about improvements include: environmental • Reduce energy consumption for protection at the unit by 10 percent licensingpPrrionctsehdouprpesla,Cnsonunibnssugil,dtiiensgHeidelbKenrEgonvpwilureobldnigcmeatetrinaotnsafnelrs,ItnfroarinmiantigonaCnendter,seminars •••• RpERfReemneeeeerdddsdi uuuuscesrlcccreieeeeo a be ncnpnyao ooi ls2naiwyim stgd meid Bnic eata yg r(toiAc nletflo)hemt2see snmi edsassegn ibl/ocimyvne e30 sar .tn5yod a lmintedarxs. overhaul of units Environmental protection at Heidelberg Printing and the Environment 7 Example showing potential savings possible with the Speedmaster SM/CD 102 Material Without Star units With Star units Saving in % Ink 1,940g 1,840g 5 Coating 5,520g 5,350g 3 IPA 1,400ml (10%+10%)* 700ml (5%+5%)* 50 Powder 440g 310g 30 Cleaning Agents 750ml 75ml 90 *IPA consumption consists of the percentage by content in the dampening solution circuit plus loss 25 50 75 100 through evaporation Input on the basis of 1 hour’s production Goals such as these are an estab- Key factors: models of peripherals from the lished part of the standardized devel- Knowledge transfer and consulting Speedmaster Star System. opment process that is in place at The impact a press has on the environ- The environmental experts at Heidelberg. By systematically analyz- ment doesn’t just depend on the Heidelberg also offer extensive con- ing environmental requirements, technology used, it is also heavily sulting services. These can include goals can be established and tested shaped by the operator’s level of environmental issues when planning before products are released on the expertise. For example, Heidelberg printshops as well as licensing pro- market. developers have constructed a device cedures for presses subject to the Product development always that enables powder to be applied German Federal Immissions Control involves teams of product managers, sparingly and consistently. It is up Act. Since several countries offer product developers, production to the operator to then select the state subsidies to encourage invest- experts and service staff working appropriate powder and a suitable ment in environmentally friendly together. In-house experts in occu- machine program. For this reason, printing technology, Heidelberg pational health and safety and envi- instructor training is taken very seri- advises companies on how to apply ronmental protection are on hand to ously at Heidelberg, since it is the for these funds. advise these teams in specialist areas. instructors who will transfer their All staff have access to instruments knowledge about e.g. optimized specially developed for Heidelberg powder application to customers. to aid in environmentally sound Only successful cooperation can product development as well as to improve air quality in the printroom. extensive material and procedural Heidelberg supports printers in databases. These also take into ac- this area with training and detailed count the very different regulatory documentation on how to operate Environmental goals of product requirements that apply to presses presses in an environmentally friend- development on the global market. ly way. This is complemented by • Reduce paper waste seminars on topics such as environ- • Minimize emissions mentally efficient printing covered by (IPA, VOCs, powder dust, etc.) the Print Media Academy’s training • Reduce noise program. Practical examples of envi- • Environmentally sound design ronmentally friendly, cost-effective of cleaning procedures and highly automated operation are • Reduce quantities of waste provided by the Environmental (ink, cleaning agents, Information Center at the company’s dampening solution, etc.) headquarter and at high-profile • Lower energy consumption international trade shows using 8 Printing and the Environment The Speedmaster Star System The Speedmaster Star System • Each component features environmentally sound solutions that make good business sense, creating the ideal conditions for high-powered production that is both profitable and kind on the environment. CombiStar CutStar (inking unit temperature control (sheeter) and dampening solution supply) WashStar (cleaning agent disposal) InkLine/InkLine Direct AirStar (ink delivery) (suction and blowing air supply) ScrollStar (compressed air supply) CoatingStar (coating supply) The Speedmaster Star System Printing and the Environment 9 The Star System stands for productiv- Save energy Reduced ink and coating ity, printing quality and reliability in • AirStar:The central suction and consumption production. It shows that profitable blast-air supply for the printing • InkLine:Automatic ink metering and environmentally sound printing press is regulated completely reduces consumption by three are perfectly compatible. The Berufs- automatically in line with con- to five percent. Virtually complete genossenschaft Druck und Papier- sumption levels. This reduces emptying of ink cartridges and verarbeitung e.V. (German Institution power consumption by up to 50 reduced fill levels in the ink foun- for Statutory Insurance and Preven- percent. tain cut ink waste and the asso- tion in the Printing and Paper Indus- • DryStar:The new dryer version ciated disposal costs. try) has awarded midsize and large delivers improved efficiency • CoatingStar:The new universal Speedmaster presses equipped with with the same connected load. coating unit with its low-main- Star products the “Emission-tested” Improved thermodynamics tenance, long-life annular piston certificate, while the German state ensure optimized heat transfer pumps helps cut setup times provides subsidies for presses to the sheet. when changing coatings and mini- equipped with the Star System. Even • The water-cooled version saves the mizes the amount of coating left in high-performance production, printshop heating costs in winter, over. the Speedmaster performs well within since with air cooling the fresh all legal emission limit values. air supplied has to be heated up Cleaner air to room temperature. In summer, • PowderStar:Targeting powder water-cooling replaces or reduces where it is needed on both sides energy consumption for air con- of the print sheet, consistent ditioning. volume metering and specific nozzle geometries cut powder Reduce paper waste consumption by up to 30 percent. • CutStar:The sheeter saves paper • CleanStar:Extraction of excess thanks to its variable cutoff powder particles from the DryStar length and more reliable and enclosed delivery and subsequent (drying) consistent printing stock feed. cleaning of exhaust air reduces • CombiStar:The combination of dust levels in the printroom by CleanStar (powder extraction) inking unit temperature control around 80 percent. and dampening solution prepa- PowderStar ration ensures optimum printing Quiet, environmentally friendly (powder application) conditions in every climate, compressed air thereby reducing paper waste. • ScrollStar:Using a screw-type compressor and an air-cooling Environmentally friendly cleaning dryer, compressed air can be • WashStar:Collects the soiled generated entirely free of oil and mixture of cleaning agent and water condensation. Sound-deadening and uses it to rinse the catch pans. console casings reduce compres- • EcoClean:The filter system can sor noise levels. reduce cleaning agent consump- tion by around 90 percent. Alcohol-reduced printing • The IPA consumption of a Speedmaster CD 74 working in three-shift operation can for example be reduced by up to 3,000 liters per year. 10 Printing and the Environment Product development highlights Product development highlights • Heidelberg project teams are committed to the continuing optimization of its presses. Four examples illus- trate how this benefits business and the environ- ment alike. Reducing paper waste the startup phase. It enables the oper- araft of individual measures all play Paper waste is an issue for every ator to briefly “over-control” the their part in reducing paper consump- printshop. It costs a lot of money and inkingunit when printing begins, tion. uses up resources, and is therefore a and supports automatic adjustments key issue in all Heidelberg’s product to the quantity of dampening solu- Environmentally friendly cleaning development work. For example, tion, and adaptation of pre- and post- Automatic washup devices can produce the inking unit temperature control dampening phases if production is savings, benefit employees’ health and maintains a constant temperature interrupted. The quality and color deliver environmental benefits. In in the inking unit. When the press control systems Prinect Image Control printshops, for example, the choice of is started up, the inking unit is and Axis Control support the printer cleaning agent and how it is handled pre-heated, then cooled down again in achieving the desired result. They are both crucial. On the technical side, during the production run. This automatically detect color deviations engineers developed a modular system increases the stability of the process and suggest corrective measures that solution that further relieves the load and reduces paper waste in the the printer can confirm online. on printshops and the environment. startup phase and production run. Reduced paper waste is also an WashStar replaces manual cleaning Remote distributor adjustment issue in Heidelberg postpress ma- of the catch pans on the blanket and allows the operator to precisely control chines. For example, sensors located impression-cylinder washup devices of lateral oscillation on the monitor. along the paper path identify even the Speedmaster 102 with a fully auto- This helps the printer to quickly get the smallest faults immediately and mated washup program. The equip- to grips with the visible reduction bring saddlestitchers, folders or other ment traps used cleaning agent in a in the ink applied between the sheet’s devices to a halt as and when required. collecting tank and removes the worst front and rear edges, and results in On saddlestitchers, technical solutions of the dirt from it. It is then ready less paper waste in the delivery. such as automatic format presetting for rinsing the catch pans. Using a ColourFast Solution software and sequential feeder monitoring also WashStar soon pays off – on one accelerates inking-up, thus reducing contribute to significantly reducing single Speedmaster SM 102-8 working unwanted paper consumption in the amount of paper waste. In this way in two-shift operation, for example, over 100 working hours and up to 30 machine hours per year can be saved. Model calculation using a midsize printshop by way of example The EcoClean filtration unit from technotrans AG adds recycling capa- Without cleaning agent With cleaning agent bilities to the system. With EcoClean, recycling recycling used cleaning agent is no longer Cleaning agent 15,000l, 15,000 Euro p.a. 1,500l, 1,500 Euro p.a. disposed of as waste, but is instead Disposal volume 28,500l, 17,100 Euro p.a. 1,425l, 855 Euro p.a. purified and re-used. Up to 90 per- Filter material 2,160 Euro p.a. cent of cleaning agent can be recycled Water treatment 450 Euro p.a. in this way, considerably reducing Total costs 32,100 Euro p.a. 4,965 Euro p.a. procurement and disposal costs. Potential savings 27,135 Euro p.a. In addition, Heidelberg certifies Payback time approx. 1.5 to 2 years cleaning agents for the automatic

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2. We implement official requirements, laws and regulations at all Heidelberg utilization phase, i.e. in the print- lished part of the standardized devel- through evaporation . cooling unit, i.e. the pump unit and the glycol recoolers. The unit typically . Fonts: Heidelberg Gothic, Heidelberg An
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