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Environmentally Friendly Printing – Environmental issues – 28th June 2010
Where more than one option is available, a careful choice must be made between one system and another with the obvious deciding factors those of capital and general running costs. However, with green issues well to the fore, the environmental impact of using any control technology is increasingly playing a key role in influencing the decision-making process.

The emotional topic of global warming caused by the continued of carbon dioxide into the atmosphere primarily by industry, has often led for calls within the European Community for a surcharge on fuel, or a Carbon Tax as it is often referred to, in a bid to make industry reduce the amount of fossil fuels consumed. Although no agreements have yet been made on such a tax, it must be borne in mind during the decision-making process as it would undoubtedly increase the costs of operating all energy dependent control systems such as thermal and catalytic incinerators.

It should be borne in mind that the combustion of one therm of natural gas will consume 16.95 lbs of oxygen, and as a by-products of the combustion process will produce 11.65 lbs of carbon dioxide. A typical printing company utilising an incinerator which consumes natural gas at the rate of 47 therms per hour would therefore be responsible for the production of 1589 tonnes of carbon dioxide per year.

In addition other gases are also produced as a by-product of the combustion process, notably nitrogen oxides, which are a contributory factor in the production of acid rain.

Environmentally Friendly Printing – Dryer optimisation
One of the principal factors in determining the size of the pollution control system required to comply with the legislation, and therefore in determining its initial capital and subsequent operating costs, is the volume of the waste gases generated by the printing process which require treating. As the volume of the gases increase so too does the size of the system required and it’s running costs.

It can be appreciated that by reducing the volume of gases generated, a much smaller emission control system is required with an associated reduction in its capital and operating costs. For all printing processes, the quantity of the waste gases generated is linked to the operating efficiency of the drying systems utilised. Therefore, as a first step in the selection of a suitable emission control system, a detailed investigation into the operation and performance of the drying system should be implemented and necessary measure carried out to ensure that it operates at peak efficiency.

The results of an intensive study of over 100 flexographic, rotogravure and coating printing plants throughout Europe illustrated that the majority of drying systems are operating well below optimum efficiency. By optimising the operation of the dryers, exhaust air flow rates are reduced significantly reductions of up to 75% can be achieved- and the size of the control system required to clean the gases reduced in scale accordingly and similarly the costs involved in its installation and operation.

Other benefits to be derived by optimising the operation of a typical drying system include:

• Reductions in energy consumption – between 30-50% on average
• Increased press machine speeds-typically up to 40%
• Reduced exhaust flow rates-up to 20% on average-smaller emission controls system
• Improved product quality- reduced solvent retention
• Reduced environmentally impact- lower CO, CO2 and nitrogen oxides.

In deciding upon the type of pollution control to install, a diverse variety of factors must be taken into account. The legislation to be applied throughout the European Community has yet to be finalised and this clearly creates problems when trying to establish a blueprint for the ideal pollution control system for any printing company.

Each system, as outlined, has significant advantages and disadvantages whether relating to their field of application, financial cost, or environmental impact. The long term running costs of a system should be established realistically well before a final decision is made with the figures quoted by the manufacturers checked by independent advisers, for these can vary widely.

Similarly, before deciding upon the size and type of control system to install, it is worthwhile establishing whether the print drying system is operating at optimum efficiency or whether improvements can be made. Failure to do so may result in the specification of a system which is far bigger than that really necessary with its associated additional costs, and which is prohibitively expensive to operate.

Clearly, where pollution control systems are concerned, taking time over the selection process, and looking pragmatically at all the options available can pay notable dividends.

Peter Harrison is Joint Managing Director of The Printing House Ltd, and Print Buying Direct of Crewe, Cheshire, UK.

We have great online print prices – Print Buying Direct are UK market Leaders and Innovators in Leaflet Printing | Brochure Printing, Large Poster Printing, Banner printing online (A1 Posters, A0 Posters etc) and Banner Stands.

For more free articles on Printing and Graphic Design see our Online Printing | Print Buying Direct Website.   For more information on printing and graphic design please see some of our recent blog articles;

• Environmentally Friendly Printing – Condensing filtration solvent recovery
• Green Printing – Carbon absorption
• Green Printing – Thermal incineration
• Green Printing – Emissions to air

Print Buying Direct is the online Trading Name of The Printing House Ltd.  One of the UK’s leading quality printing companies for graphic design, short run digital printing, long run litho printing and large format colour printing. Based in Crewe, Cheshire (Cheshire Printers), in the North West of England – delivering to customers across the UK and Europe.

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