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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