Sustainable Platemaking 2011 Update Ray Bodwell. 2 Agenda Recap - Sustainability Pressures Across...

Sustainable Platemaking2011 Update

Ray Bodwell

2

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


6

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.


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


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Logistics

Sourcing

Carbon Footprint Strategy

Waste Disposal

Packaging / Product Design

““Greening the Supply Chain”Greening the Supply 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.


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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.


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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)


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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.


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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


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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


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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


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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


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


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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


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


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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


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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


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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


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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


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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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[email protected]

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Thank you!

[email protected]

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Advancing FlexographyAdvancing Flexography

Sustainable Platemaking 2011 Update Ray Bodwell. 2 Agenda Recap - Sustainability Pressures Across...

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