Environmental protection at Heidelberg

16 Pages·2004·0.32 MB·English

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,
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Integrated n about improvements include:
environmental • Reduce energy consumption for
protection at the unit by 10 percent
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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