Simplification of pcr for Printed products 20120930

Simplification of PCR for Printed productsCarbon calculation by10-selected item

Dr. SHIMIZU, HirokazuPresident, SHIMIZU PRINTING INC.

Visiting Senior Researcher, Waseda University Environmental Research InstituteExpert, ISO130 (Graphic technology) WG11(Environmental impact of printed matters)

1

Nagata Laboratory, Waseda University Graduate School of Environment and Energy Engineering

Motivations1. Complicated PCR should be reformed

• Time-consuming work is big wall for SMEs• Detailed calc. is not equal to “Sophistication”

2. New thought by new CFP program holder• CFP should be utilized for “business”• More than one PCR can exist for same product

3. New concept for SMEs• Carbon calculator can be PCR• Reduce manpower for calculating work

2

Waseda University Environmental Research Institute

Shimizu Printing Inc.

Agenda1. Promotion of new PCR for Printing

• Select only 10-item for simplification• Points of modifying current PCR• Accuracy of PCR for Printing by case studies• Conclusion of new PCR accuracy

2. Accuracy of existing PCR for Printing• The difference by emission factors of paper• The difference by calculation methods• Conclusion of current PCR accuracy

3. Summary• Magnitude of fluctuation of new/current PCR• Utilization of CFP

3



1.Promotion of new PCR for Printing (cont’d)

Select only 10-item for simplification(1)Substrate(2)Transportation for substrate(3)Ink & varnish(4)Transportation for Ink & varnish(5)Plate (waterless printing)(6)Transportation for Plate(7)Printing process (waterless printing)(8)Post-press process(9)Distribution(10)Waste & Recycle

4


Water (dampening solution)Additive (dampening solution)

Prepress(editing, designing, CtP)

Wrapping material for delivery

Material (glue, stitch...)


NOT calculated

1.Promotion of new PCR for Printing

Points of modifying current PCRI. Calculation method is unified for “cumulative”

II. Modelization for thickness of ink/varnish

III. Electricity usage = Rated output × fixed loading factor

IV. Loading percentage of truck is fixed at 50%

V. Calculate incineration by coated layer of paper only

VI. Printed products only by waterless printing method

VII.Avoid “scenario setting” of key items

5



1.Promotion of new PCR for Printing (cont’d)Points of modifying current PCR

6


7.Pr

intin

g pr

oces

s (e

lect

ricity

for m

achi

nes,

ligh

ting,

air-

cond

.)

8.Po

stpr

ess

proc

ess

(ele

ctric

ity fo

r mac

hine

s, li

ghtin

g, a

ir-co

nd.)

10.W

aste

from

hou

seho

ld, R

ecyc

le fr

om fa

ctor

y an

d ho

useh

old

1.Su

bstr

ate

(pap

er/p

last

ic)

9.De

liver

y (e

xclu

ding

pac

king

mat

eria

ls)

2. T

rans

. for

Sub

stra

te (t

ruck

s/ra

il/su

rfac

e/ai

r)

3.In

k &

var

nish

(con

v./U

V in

k, O

P va

rnis

h, C

oatin

g va

rnis

h)

4.Tr

ans.

for I

nk &

var

nish

(tru

cks/

rail/

surf

ace/

air)

5.Pl

ate

(for

wat

erle

ss p

rintin

g)

6.Tr

ans.

for P

late

(tru

cks/

rail/

surf

ace/

air)

Raw material acquisition Production Distribution Waste/Recycle



7


Accuracy of new PCR for Printing by case studies (Paper package for DVD)


## Item100000 0 copies 30000 copies 10000 copies 5000 c copies 500 c copies

Itemkg-CO2e % kg-CO2e % kg-CO2e % kg-CO2e % kg-CO2e %

1

2

3

4

5

6

7

8

9

10-

Substrate 2104.4 69.6 701.4 64.3 300.6 58.5 200.4 52.5 110.2 41.6

Trans. for Subs. 207.6 6.9 69.2 6.3 29.7 5.8 19.8 5.2 10.9 4.1

Ink&varnish 55.3 1.8 18.5 1.7 17.9 1.5 5.3 1.4 2.9 1.1

Trans. for Ink&varnish 0.2 0.0 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Plate 36.2 1.2 36.2 3.3 36.2 7.0 36.2 9.5 36.2 13.7

Trans. for Plate 0.1 0.0 0.1 0.0 0.1 0.0 0.1 0.0 0.1 0.0

Printing process 170.6 5.6 85.3 7.8 42.6 8.3 42.6 11.2 42.6 16.1

Postpress process 180.2 6.0 58.4 5.4 21.3 4.1 13.4 3.5 7.0 2.6

Delivery 25.9 1.0 11.4 1.0 3.8 0.7 1.9 0.5 0.2 0.1

Waste & Recycle 193.6 6.4 61.4 5.6 23.6 4.6 14.2 3.7 5.8 2.2

Others 51.3 1.7 48.8 4.5 48.2 9.4 47.9 12.5 49.1 18.5

Total 3025.4 100.0 1090.8 100.0 514.0 100.0 381.8 100.0 265.0 100.0

Per copy 0.030 - 0.036 - 0.051 - 0.076 - 0.530 -


8


Accuracy of new PCR for Printing by case studies (Paper package for DVD)


0%

25%

50%

75%

100%

10000030000

100005000

500

SubstrateTrans. for Subs.Ink&varnishTrans. for Ink&varnishPlateTrans. for PlatePrinting processPostpress processDeliveryWaste & RecycleOthers


9


Accuracy of new PCR for Printing by case studies (Flyer from 300-500,000)


01020

30

40

50

60

70

80

90

100

300 5001000 1000

20002000

33005000

50005000

1000010000

1000010000

1500020000

30000500000

other items 10 items %


10


Accuracy of new PCR for Printing by case studies (Booklet from 410-500,000)


0

10

20

30

40

50

60

70

80

90

100

410 500 1000 1300 2000 2000 2400 27004000 4500

5000 50009500

1000010000

1800018000

3000050000

100000

other items 10 items %


Conclusion of new PCR accuracyCarbon calc. by 10-selected item

Package1.7% ～ 18.5% of “Others” by Shimizu Printing

Flyer2.8% ～ 22.6% of “Others” by 18 cases

Booklet1.7% ～ 27.8% of “Others” by 38 cases

11


Shimizu Printing Inc. Current PCR can provide absolute carbon calc. result?

New PCR has “missing piece” of carbon calc. result

2.Accuracy of current PCR for PrintingThe difference by emission factor (EF) of paper

(1) Magazine, 210mm*297mm, 4P+44P, 4000copies

(2) Coated card for cover, 210gsm, UV4C+PP lamination

(3) Light coated paper for text, 127.9gsm, UV4C/UV4C

(4) EF of text is calculated by weighting 6 factories (48.2%)

(5) Max. EF=1.419kg-CO2e/kg, Min.=0.704kg-CO2e/kg

(6) Weighted EF=1.197kg-CO2e/kg

(7) Sensitivity analysis by different EF of Light coated paper

(8) What I use for text is Avg./Max./Min.?

12



Reference：JLCA-LCA database 2012yr.1st edition

2.Accuracy of current PCR for Printing (cont’d)

13


The difference by EF of paper (Magazine, 4000 copies)

Shimizu Printing Inc. 0250500

750

1000

1250

1500

1750

2000

2250

1384.94 1541.192

913.137

Avg. E.F.

Max. E.F.

Min. E.F.

PaperInkPlateAdditivesDesign/EditingCtPPressPostpressWaterDeliveryWasteRecycle+7.1%

-21.5%

kg-CO2e


The difference by calc. method(1) Paper package for DVD, 130mm*130mm*9mm,

100,000copies

(2) Coated cardboard, 360gsm, UV4C+UVOP varnish

(3) EF is calculated by weighting 4 factories (86.8%)

(4) Calculated based on Cumulative method for 1,000-100,000

(5) Calculated based on Allocation method for 1,000-100,000 (allocation basis is based on paper input)

(6) Current PCR allows printers to utilize both methods

(7) Who can consider the difference between two methods?

14




15


The difference by calc. method (Paper package for DVD)


CopiesCumulative Allocation % (Allocation/Copiesg-CO2e/copy g-CO2e/copy

Cumulative)

1000 276.075 223.708 81.02500 126.353 113.372 89.75000 76.362 71.132 93.27500 59.739 59.276 99.210000 51.398 53.349 103.820000 41.328 44.457 107.630000 36.359 41.493 114.140000 33.880 40.011 118.150000 32.389 39.122 120.860000 32.199 38.530 119.770000 31.375 38.106 121.580000 31.291 37.789 120.890000 30.811 37.542 121.8100000 30.254 37.344 123.4


16


The difference by calc. method (Paper package for DVD)


0

50

100

150

200

250

300

1000 2500 5000 7500 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000

Cumulative Allocation


Conclusion of current PCR accuracyCarbon calc. by different EFs

+7.1% ～ -21.5% compared to avg. dataCarbon calc. by different calc. methods

+23.4% ～ -19.0% compared to cumulative method

17



No absolute number from carbon calculation

Current PCR has certain range of carbon calc. result

3.SummaryMagnitude of fluctuation by new/current PCR

18



0

32.5

65

97.5

130

77.4

72.2 78.581

97.2 98.3 107.1

123.4

10-item(flyer)10-item(Booklet)

Paper EF

Allo./Cum.

Min. Max. %

Current PCR

3.Summary (cont’d)

Utilization of CFP by simplification of PCRa. Find “Hotspot(s)” to improve manufacturing process

and/or select eco-friendly materialb. Communicate with print-buyers (consumers) by

showing comprehensive internal comparisonc. Conduct many pilot projects to know efficiency of

CFP (environment impact assessment)

19



CFP should be utilized for sales growth and cost-cut, not for academic experts to be satisfied

Simplification of calculation is extremely important to save time and money, “Detailed calculation cannot guarantee accuracy!”

20



Thank you for your attention.You can have a look at this presentation file:

http://www.slideshare.net/ShimizuHiro/edit_my_uploads

Business

Simplification of pcr for Printed products 20120930