Sustainable Platemaking2011 Update
Ray Bodwell
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AgendaAgenda
Recap - Sustainability Pressures Across Value Chain
DuPont & Sustainability
Cyrel® and Sustainability
TR3 – Return, Reuse, Recycle
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Sustainable Packaging Scorecard
To drive improvement in their packaging supply chain…
• Renewable energy used (5% weighting)• Greenhouse gas emissions (life cycle) (15%
weighting)• Package to product ratio (15% weighting)• Cube Utilization (15% weighting)• Transportation – Ave. distance package travels
from mfg site to filling point. (10% weighting)• Recycle content (10% weighting)• Recovery Value / Recyclability of materials
used (10% weighting)• Material Value (15% weighting)• Innovations to use less energy (5% weighting)
The Original Push: Wal-Mart 7R’s & ScorecardThe Original Push: Wal-Mart 7R’s & Scorecard
7 “R’s” of Packaging by Wal-Mart
1. Remove (getting rid of unneeded packaging altogether).
2. Reduce (reducing the amount of packaging – source reduction.
3. Reuse (utilizing reusable packaging where possible).
4. Renew(able) (using renewable-resource-based packaging and renewable energy when possible).
5. Recycle(able) (using packaging materials that are made from recycled materials or can be recycled easily).
6. Revenue (not increasing the system cost of packaging).
7. Read (using packaging to educate the public about the benefits being delivered).
Drivers Across the Value Chain
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W-M SustProdIndex 15 Questions
Drivers Across the Value Chain
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Extended Producer Responsibility (EPR) uses political means to hold producers liable for the costs of managing their products at end of life. EPR focuses on the creation of 'cradle to cradle' recycling systems designed, financed, and managed by the producers themselves.
Global DriversGlobal Drivers
It’s no longer a question of whether or not EPR will come to America; it’s only a question of when and on whose terms.” Julian Carroll,EUROPEN
Consumer Goods Forum (Global Packaging Project) • ISO Committee met in January, 2010 in Toronto • Develop international standards for source reduction, reuse, recycling, energy recovery, chemical recovery composting and biodegradation within 2 years.
Drivers Across the Value Chain
EUROPEN – The European Organization for Packaging and the Environment
Sustainability Consortium • Administered by Arizona State & U. of Arkansas•Cradle to grave view of products & packaging• Global Index
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Sustainable Packaging CoalitionSustainable Packaging Coalition
Is beneficial, safe and healthy for individuals & communities throughout its life cycle
Meets market criteria for performance & cost
Is sourced, manufactured, transported & recycled using renewable energy
Optimizes the use of renewable or recycled source materials
Is manufactured using clean production technologies & best practices
Is made from materials healthy in all probable end-of-life scenarios
Is physically designed to optimize materials & energy
Is effectively recovered and utilized in biological and/or industrial closed loop cycles
Material Use
Clean Production
Technologies
Community Impact
Water Use
Cost & Performance
Energy Use
Material Health
Worker ImpactSPC Definition of Sustainable Packaging
Drivers Across the Value Chain
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Logistics
Sourcing
Carbon Footprint Strategy
Waste Disposal
Packaging / Product Design
““Greening the Supply Chain”Greening the Supply Chain”
Drivers Across the Value Chain
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The creation of shareholder and societal value while we reduce the environmental footprint* along the value chains in which we operate.
DuPont Mission – Sustainable GrowthDuPont Mission – Sustainable Growth
* DuPont defines “footprint’ as all injuries, illnesses, incidents, waste, emissions, use of water and depletable forms of raw materials
and energy.
DuPont & Sustainability
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DuPont “Scorecard” & Systems Thinking - 2006Downstream Assessment Criteria
Raw Material Acquisition
Transportation Manufacturing Use/Reuse/ Maintenance
Transportation Waste Management
Waterborne Wastes
Air EmissionsCo-products
Solid Wastes
RecycleUp Stream
Raw Materials Energy
Down Stream
1. Greenhouse gas emissions
2. Energy consumption
3. Impact on air and water pollution
4. Material consumption & recycled content
5. Non-depletable resources inherent in our product and/or enabled in the value chain
6. Waste generation
7. Ease of disposal; hazardous waste content; recyclability and biodegradability
8. Impact on ecosystems, land use, or biological diversity
9. Impact on water quality or consumption
10.Toxicological risk to human health
11.Cradle-to-Gate Product Footprint – Material and energy use, emissions and waste associated with product manufacture and upstream processes.
DuPont & Sustainability
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We Do Take Actually It SeriouslyWe Do Take Actually It Seriously
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First objective : Benchmark the environmental performance of Flexography versus Rotogravure printing for the flexible packaging and tag & label markets.
Functional unit = area of printed substrate (m2)
Second objective :Compare the environmental performance of solvent-based and thermal (Cyrel® FAST) flexographic plate imaging technology.
Note : Liquid and water washable plates were not included in this study.
Functional unit = area of imaged plate (m2)
DuPont – LCA’sDuPont – LCA’s
DuPont Life Cycle Analysis
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A tool to evaluate the environmental footprint of a product or process.
Evaluates all upstream and downstream products and processes.
Examines materials, energy & key environmental releases.
Conducted under ISO 14040-44
Critical review by qualified 3rd parties
The critical review ensures that :
• The methods used to carry out the LCA are consistent with this International Standard
• The methods used in the LCA are scientifically and technically valid
• The data used are appropriate and reasonable in relation to the study goal
• The study report is transparent and consistent
Definition: Life Cycle Assessment (LCA)Definition: Life Cycle Assessment (LCA)
DuPont Life Cycle Analysis
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Results…Results…
2nd step : Update data from 2009-2010 publication in April 2010
data from 2006-2007 publication in September 2008
1st step : Original LCA
Reason for update.
The original study was based on equipment electricity use measurements, without accounting for any idle time or variations in equipment loading.
Original measurements were collected over thirteen weeks. An eight week period of continuous data collection was used for the update.
DuPont Life Cycle Analysis
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Ink & Solvent Production
Electricity
Substrate Film
Combusted VOCs
Dryer & Oxidizer Fuel
Heat Credit & Recycling
Plate or Cylinder
Cardboard Cores
Flexography : • Higher viscosity inks reduces solvent use• Reduced energy & emissions for drying• Reduced substrate waste
Aligned Plastic Substrate Model
Non
-Ren
ewab
le E
nerg
y U
se (M
J pe
r m2
of p
rodu
ct)
Gre
enho
use
Gas
Em
issi
ons
(kg
CO
2 e
per m
2 of
pro
duct
)
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
Average AlignedFlexo
Average AlignedGravure
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
Average AlignedFlexo
Average AlignedGravure
Original LCA Original LCA Flexography vs. RotogravureFlexography vs. Rotogravure
Average 50% Savings with Flexographic Printing
DuPont Life Cycle Analysis
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Estimated Savings: Flexography vs. Gravure Estimated Savings: Flexography vs. Gravure
Data Source: http://www.usctcgateway.net/tool/
Non-renewable energy savings equivalent to 25,000 gallons of gasoline
Greenhouse gas emissions savings equivalent to taking 39 average US passenger cars off the road for one year
* Based on DuPont Life Cycle Assessment
Changing 10 Million ft2 of Printed Substrate from Gravure to Flexographic Printing
DuPont Life Cycle Analysis
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Total Production Time: 30 – 45 mins.
Total Production Time: 2.5 – 4.0 hours
Film/Analog
Laser/Digital
Solvent Process
Film/Analog
Thermal Process
Laser/Digital
Plate Processing WorkflowsPlate Processing Workflows
DuPont Life Cycle Analysis
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Average Digital Flexographic Plate Imaging Impact Average Digital Flexographic Plate Imaging Impact
0
50
100
150
200
250
0.067 UpdatedDigital Solvent
Average
0.067 DigitalThermal
No
n-R
en
ew
ab
le E
ne
rgy
Co
ns
um
pti
on
(MJ
/ m
2 )
Solvent & Recycle
Light Finisher
Dryer
Processor & Developer
Main Exposure
Ablate Image
Back Exposure
216
81
0
2
4
6
8
10
12
14
16
18
0.067 UpdatedDigital Solvent
Average
0.067 DigitalThermal
Gre
en
ho
us
e G
as
Em
iss
ion
s
(kg
eq
. CO
2 / m
2 )
15.2
7.3
Cyrel® FAST has a 52% lower greenhouse
gas emissions.
Cyrel® FAST has a 63% lower non-renewable
energy consumption
* With DR 44 fiberweb
DuPont Life Cycle Analysis
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Updated LCA Results – Solvent vs.. ThermalUpdated LCA Results – Solvent vs.. Thermal
0
50
100
150
200
250
0.067OriginalDigitalSolventAverage
0.067UpdatedDigitalSolventAverage
0.067Digital
Thermal
No
n-R
en
ew
ab
le E
ne
rgy
Co
ns
um
pti
on
(MJ
/ m
2 )
Solvent & Recycle
Light Finisher
Dryer
Processor & Fiberweb
Main Exposure
Ablate Image
Back Exposure
0
2
4
6
8
10
12
14
16
18
0.067OriginalDigitalSolventAverage
0.067UpdatedDigitalSolventAverage
0.067 DigitalThermal
Gre
en
ho
us
e G
as
Em
iss
ion
s
(kg
eq
. CO
2 / m
2 )
Figure 1: Average Digital Flexographic Plate Imaging Impact
Digital thermal = 63% lower energy & 53% lower ghg vs. solvent
DuPont Life Cycle Analysis
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Estimated Savings: Solvent-free SystemEstimated Savings: Solvent-free System
* Based on DuPont Life Cycle Assessment
Data Source: http://www.usctcgateway.net/tool/
Non-renewable energy savings equivalent to 8,750 gallons of gasoline
Greenhouse gas emissions savings equivalent to taking 16 average US passenger cars off the road for one year
Changing 100,000 ft2 of Digital Flexo Plates from Solvent Processing to Cyrel® FAST Thermal System
DuPont Life Cycle Analysis
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Down-gauging:
Reduces overall
footprint Reduces drying time Reduces solvent use &
recycling Reduces energy
consumption & greenhouse gases
Based on DuPont Life Cycle Assessment Study
Gre
enho
use
Gas
Em
issi
ons
kg
eq.C
O2 /
ft2
Non
rene
wab
le E
nerg
y C
onsu
mpt
ion
(MJ/
ft2 )
Back ExposureSolvent & Recycle
Dryer
Light Finisher
Processor & Fiberweb
Main Exposure
0
5
10
15
20
25
0.067AnalogSolvent
0.112AnalogSolvent
0.25AnalogSolvent
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
0.067AnalogSolvent
0.112AnalogSolvent
0.25AnalogSolvent
Source Reductions through Down-gaugingSource Reductions through Down-gauging
Other benefits:
Less board strength losses
Improved graphics
Supply chain reductions
DuPont Life Cycle Analysis
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Does This Really Matter?Does This Really Matter?
• Yes Gravure vs. Flexo is meaningful and should matter to Wal-Mart
• Yes Thermal vs. solvent also impactful over time, volume and multiple SKU’s
• Yes Down gauging plates has a measureable energy and CO2 savings that can also be impactful over time, volume and multiple SKU’s
What about liquid and water wash plates?What about liquid and water wash plates?• We don’t make them so we didn’t measure them
• All questions about energy and carbon footprint apply• Follow ISO 14040 Guidelines
• Key questions around water consumption and waste water generation
DuPont Life Cycle Analysis
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Liquid Platemaking QuestionLiquid Platemaking Question
How Sustainable is it?
Film Processing
• Water is used in developer and fixer tanks
• Used water and chemicals go down the drain when baths are replenished
• Silver (heavy metals) is recovered but some traces of silver goes down the drain
Platemaking
• Using an increasingly precious natural resource (water) for processing and post exposure steps
• Post exposure bath changed every 2-3 days
• Unexposed monomer goes down the drain!!
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Wal-Mart* and Water UseWal-Mart* and Water Use
Mike Duke, President and CEO of Wal-Mart Sustainability Milestone Meeting - July 16, 2009
“You will also see some new areas that we are asking about, including water use and solid waste. These are not complicated questions, but we have never systematically asked for this kind of information before”.
Why is water use efficiency important?
Water efficiency issues are becoming increasingly vital: “Demand for water is doubling every 20 years, outpacing population growth twice as fast. Currently 1.3 billion people don’t have access to clean water and 2.5 billion lack proper sewage and sanitation. According to estimates, demand for freshwater will exceed the world’s supply by over 50 percent in less than 20 years.”* In light of these facts, businesses have an obligation to use water resources responsibly, and the increasing scarcity of water could raise the cost of doing business. Companies in water-intensive industries face increasing water-related physical, regulatory and reputational risks.**
Have you set publically available water use reduction targets? If yes, what are those targets?
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Water Considerations Water Considerations Aging infrastructure, climate change, strained city budgets
RI Considers Raising Water Bills to Protect Supply By THE ASSOCIATED PRESS
Published: October 5, 2009
Water rates in Thousand Oaks (IL) will go up in November and again in July despite the pleas of residents who asked the City Council to protect them from higher water costs.
Associated PressFebruary 5, 2008 The government projects that at least 36 states will face water shortages within five years because of rising temperatures, drought, population growth, urban sprawl, waste and excess.
OCEANSIDE (CA): City eyes big boost to water, sewer rates Much of increase is to cover higher rates charged by water suppliers nctimes.com | Posted: Friday, October 9, 2009
DuPont Life Cycle Analysis
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But it’s not just about plate processingWaste: The Goal is ZeroWaste: The Goal is Zero
Goal: Expand and develop suitable recovery, reuse or recycling options for all Plant waste & everything that we ship to Customers
PACKAGING Waste– e.g. polystyrene, gaylords, foam…
PLATE Waste – Plates, Trim,
CONSUMABLES – butt rolls, base & cover sheets, Binders, Polymers
TODAY
Products & Packaging
Waste
Customer
Manufacturing
Reuse Applications
New Commercial Applications
Post Manufacturing
Recover, Reuse, Recycle
IncinerationIncineration
ReuseReuseEnergy-
from-Waste
2009
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What is driving the change? What is driving the change?
• US generates about 370 million tons of waste per year• Only 27% is currently recycled• 8% waste to energy• 66% Landfills
• Number of Landfills in US has decreased by 75% in 20 years• 1990: 8000 Today: 1800• Stricter landfill regulations• Increasing pressure to close or rationalize landfills• Decreasing public tolerance for landfilling• The cost for landfills will continue to increase
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DuPont TR3 – Return, Reuse, RecycleDuPont TR3 – Return, Reuse, Recycle
Sustainability Program
Return all plate and packaging material for reuse or recycle
Everything that leaves Parlin is returned & reused or recycled
That includes:
Parlin manufacturing waste – edge trim & yield losses
Our customers waste – edge trim & scrap
Downstream printers waste – printed plates
All packaging materials – boxes, polystyrene sheets, etc.
Used developer rolls
Cover sheets
Chemistry (still bottoms)
Package &
Distribute
Acquire Raw
Materials
Use, Reuse & Maintain
Disposal or
Recycling
Design & Produce
Cradle-to-Grave
Cradle-to-Gate
DuPont TR3
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Finding a competent, responsible recycler
This is not as simple as putting the waste out on the curb!
We have a cradle-to-grave stewardship responsibility
It is very important to know what the recycler does with the material
To understand potential end uses
To understand end use safety concerns
To understand any recycle process hazards
We’ve chosen a recycler that is:
• Very competent technically – understands polymer chemistry
• Financially stable
• Centrally located with our plant and customers
• Has successfully satisfied all of our stewardship criteria
Recycling Challenges – Who to partner with?Recycling Challenges – Who to partner with?
DuPont TR3
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Recycling Challenges – LogisticsRecycling Challenges – Logistics
Logistics costs must be very well managed Transportation can range from $.20 to $.60 per lb
Often more expensive LTL (Less than Truckload Lot) Getting enough weight in a box is a challenge
Volume is critical metric so return boxes must be full And ultimately, the material is worth only a few cents per lb.
Partnered with third party logistics supplier Has been recycling some Cyrel packaging materials for 10 – 20
years Currently handles recycle for several other DuPont businesses Has a national network of warehouses and consolidation points Has relationships and favorable rates with many local trucking firms Has processes in place to arrange and manage all required
transportation
DuPont TR3
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TR3 At no cost to the CustomerTR3 At no cost to the Customer
If the customer: Returns ~ all Cyrel® boxes in fully reusable condition
Returns polystyrene in the boxes
Returns all developer rolls
Returns PET cover sheets
Maximizes plate waste weight in a gaylord (Target is 800 lbs*)
Then DuPont will: Will absorb all costs including transportation
Provide empty gaylords and pallets if needed
So where’s the catch?
DuPont TR3
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Cover Sheets:
• Cyrel Boxes or Gaylords
Raw (Unprocessed):
• Carrier bins to Gaylords or Gaylords directly
• Lay flat to maximize weight
Fully Processed:
• Carrier bins to Gaylords or Gaylords directly
• Printed plates: Clean remove sticky back
• Lay flat to maximize weight
Polymer Separation RequirementsPolymer Separation Requirements
DuPont TR3
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Box Filling RequirementsBox Filling Requirements
Shipping costs are the most expensive component of the program
Shipping costs go up as weight in a box goes down
It costs twice as much (per pound) to ship a 400 lb gaylord vs. an 800 lb gaylord
We have targeted 800 lbs as the minimum gaylord weight
Field testing customer averaging 815 lbs
DuPont TR3
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Program StatusProgram Status
In external evaluation > 1-year
Phased roll-out going forward
Initially East of the Rockies
Looking to add ~ 40 more accounts in 2011
Contact your local DuPont Technical Sales Rep
DuPont TR3
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Additional Resources
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Resources – Sustainability Best PracticesResources – Sustainability Best [email protected]
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Resources – DuPont LCA ReportsResources – DuPont LCA [email protected]
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Advancing FlexographyAdvancing Flexography