FESPA WORLD Issue 54 (Part 2) - English

19 WORLD Green Issue Feb 2009

THE CASE FOR UV

UV LED technology under the spotlight

More and more large format printers are now employing UV technology and many are now also opting for UV LED. Printer manufacturer, Mimaki, explains the pros and cons of both technologies.

Inkjet printing is a complex

technology that encompasses

machines, printheads, inks and

substrates, all of which need

to complement each other in

order to achieve good results. But the

demands of specific applications play

an important role in determining which

large and superwide format printer is

most suitable. If we take a look at the

technologies and their implications, we

can see that inkjet is a non-contact printing

method for highly precise direct printing

on to concave, convex and flat material

surfaces. Traditional screenprinting and

service providers to print on to many types

of plastics, as well as different substrates,

thus offering a broad spectrum of

applications.

However, the UV lamps used in this

process generate a lot of heat, which

restricts the kind of substrate that is suitable

for UV printing. In addition, the whole UV

light spectrum is output.

UV LEDNewer printers, such as Mimaki’s UJV-160,

use another radiation source for the curing

process: UV LEDs. These consist of UV light

diodes that emit rays within a narrow UV

light range. Inks whose monomers have

been sensitised to this specific range can

be cured via the same process used by

UV lamps. As UV diodes do not generate

heat, many more substrates, such as

membrane switches, heat-sensitive PVC

and other plastics, films and papers

can be successfully used, broadening

the choice of applications that can be

produced. Additionally, the warm up and

cool down time necessary with UV lamps

is eliminated. UV LEDs can be switched on

and off immediately. Power consumption

UV lamp UV LED

Power consumption High Low

Lifetime Short Long

Heat generation High Low

Printable Substrates Plastics, Papers, Glass,

Cartonboard, concave

and flat substrates,

Polyesters, Foam board,

Styrene, Wood, Stone,

Polycarbonates, Acrylics,

PVC, Aluminum, Metal

Plastics (including heat-

sensitive plastics), Vinyl,

Banner, Canvas, Film,

Membrane Switches,

Papers, Glass, Cartonboard,

concave and flat

substrates, Polyesters, Foam

board, Styrene, Wood,

Stone, Polycarbonates,

Acrylics, PVC, Aluminum

Metal

Applications Accessories (leather belts,

etc), Art reproduction,

Backlit Graphics,

Construction signs,

Displays, Exhibition signs,

Lenticular, ID cards, Logos

(3D), Operation panels,

Relational gifts, Clothing

accessories, Golf balls,

Machine name plates and

operation panels, Magnets,

Mobile phone covers, Pens,

Novelties, Giveaways,

Signs, Stickers, Giftshop

articles

Floor Graphics, Vehicle

wrapping, Posters,

Banners, Indoor graphics,

Labels, Film, Accessories

(leather belts, etc), Art

reproduction, Backlit

Graphics, Construction

signs, Displays, Exhibition

signs, Lenticular, ID cards,

Logos (3D), Operation

panels, Relational gifts,

Clothing accessories,

Machine name plates and

operation panels, Novelties,

Giveaways, Signs, Stickers,

Giftshop articles

Environmental footprint High Low

non contact printing principle

UV/UV LED comparison

pad printing methods find it more difficult

to print on to uneven surfaces, but brilliant

colours, full-colour photo image data and

even smooth gradations are achieved by

inkjet printing methods.

Inkjet printers which use UV curable

inks need to cure the ink because it

incorporates monomers, a liquid with

very small molecules that need to be

fused together in a process known as

polymerisation, in order to fix them firmly

on to the material. When the particles are

exposed to UV light, they are cured, to

fuse the molecules together, as well as to

make them adhere to the substrate. This

polymerising reaction is called monomer

binding. UV curable ink, which cures soon

after printing, does not usually contain

VOCs (volatile organic compounds) and is

therefore environmentally friendly. Direct

printing on to non-absorbent materials

is possible, as the coated layers of the

resinous polymers produce printed images

on the surface of the materials. The ink

is instantly dried after irradiation with UV

light. This explains why UV ink does not

seep into the surface and ink penetration

is kept to a minimum. UV ink enables print


THE CASE FOR UV

Durst backs UV

Durst, from the outset of its

inkjet business, has only

been concerned with

environmentally friendly

printing processes. That

is why it has exclusively followed the UV

curing ink route. Durst Rho inks contain no

VOCs and strictly conform to the ‘Restriction

of Hazardous Substances’ (RoHS) Directive

2002/96/EC and Waste Electrical and

Electronic Equipment (WEEE) Directive

2002/96/EC. This means that Durst’s Rho

inks do not have to carry the symbol of the

‘dead fish’ or ‘dead tree’.

Many printers may seem unaware of

the fact that UV curing inks with “very low”

solvents, or VOC free inks, which include

photo initiators, can still contaminate the

water table and therefore have to carry

the mark of the ‘dead fish’ or the ‘dead

tree’. They might believe that by just using

UV inks they are fully conforming to the

growing requests from their customers who

are, in general, becoming much more

environmentally aware.

Many large organisations with real

environmental protection philosophies,

such as Starbucks or Ben & Jerry’s, are

looking at the complete process of how

print, including the media, recyclability,

and ink, conforms to their environmental

platform.

Durst has looked at the whole aspect of

recyclability of its inks and independent

tests carried out by the Institute for Paper

Science and Technology in Darmstadt,

Germany have certified that Durst Rho

inks printed onto corrugated board are

‘recyclable’ according to PTS-RH:21/97.

Rho inks have been further tested and

meet Toy Standard EN71 Part 3, which

limits the concentration of specific heavy

metals in the coatings used for toys,

including antimony, arsenic, barium,

cadmium, chromium, lead, mercury and

selenium. Durst has also recently applied

for the ‘The Nordic Swan’ symbol – a

world-leading Ecolabel, for its Rho inks.

The Nordic Ecolabel was established in

1989 by the Nordic Council of Ministers,

with the purpose of providing an

environmental labelling system which will

contribute to sustainable consumerism.

It was also initiated as a practical tool for

consumers, to help them actively choose

environmentally sound products. In the

case of inks, the Nordic Ecolabelling

covers the following classifications:

environment hazard; toxicity; problematic

substances; and volatile organic

substances (VOCs).

Caring for the environment

also includes the materials used in

constructing the printer, e.g. the total

energy consumption and, in particular,

that used by the UV lamps, the quantity

of ink required for flushing or purging

in order to maintain the printheads,

and the recyclability of the printed inks

and substrate. Typically, a Durst printer

will require purging once a day. It is not

uncommon for machines from other

manufacturers to require purging up to

five or six times per day. This of course,

not only wastes between 400 and 450ml

of ink per shift and, over the year, more

than 125 litres, but is also very damaging

to the environment, and the print service

provider’s pocket!

Durst is concerned with all the above

factors in the manufacture of its machines,

and its extensive R & D programme

continues to have environmental issues at

the forefront of its work, now and for the

foreseeable future.

For further information visit:

www.durst-online.com

of the respective machines is significantly

reduced, as not only do the LEDs need less

power; they can also be switched off when

they are not needed. The lifetime of UV

LEDs is far higher than that of conventional

UV lamps.

Mimaki offers a wide range of UV inkjet

solutions, as well as the new state-of-the-

art UV LED UJV-160 hybrid large format

printer. High image quality is ensured with

variable droplets and a resolution of up to

1200 x 1200 dpi. To accommodate different

media thicknesses, an automatic head

height mechanism is employed to avoid

head strikes and other undesirable issues.

The UJV-160 comes complete with two

Monomer (low molecule) (liquid ink)

Monomer (low molecular) bindingpolymerizing reaction)

Polymer (high molecule)Resinous printed material

UV light

UV curing process

tables for feed and delivery, enabling print

service providers to print on to light/rigid

materials as well as roll to roll. The UJV-160

combines the productivity, efficiency and

environmental features that future-oriented

print service providers require.

In combination with Mimaki’s UV

flexible inks for UV LED printing, the

range of applications can be further

broadened. These inks do not crack

when bent, as their surface tension can

tolerate expansions of up to 200 percent,

thus making them ideal for printing on to

uneven and curved surfaces.


www.mimaki.jp

GREEN PRINTERS


Simpson Group leads the way

Sarah Weir, General Manager at Simpson Group, highlights the company’s green strategies.A

t Simpson Group we

have always been

environmentally aware,

working with our suppliers

to reduce and eliminate,

where possible, the solvent content of

our inks and stencil cleaners. With the

installation of the Man Roland Large

Format Litho press and the Fujifilm CTP

developer, we worked with our authorised

hazardous waste collector to treat the

chemicals so they were safe to discharge

to trade effluent. Added to that, our new

bespoke headquarters was designed with

the latest environmental considerations in

mind, including interceptor tanks in the

car parks to collect any oil spillages and

leaks from vehicles.

Over recent years we have noticed a

greater drive from

our clients, pushing

more and more

for us to help them

demonstrate green

credentials throughout

their supply chains. Whilst we had always

complied with ISO 14001, it was not one of

our recognised accreditations.

In 2005 we took the decision to work

towards PAS 75, the recently developed

‘Publicly Available Standard for Excellence

in Service’, within the print industry. This

decision took us another step closer to

improving our environmental strategies,

including the documentation of them,

to satisfy an integral clause within the

standard directed at Environmental

Management Systems (EMS).

Throughout 2007, more and more

clients and prospects began to ask for their

POS materials to be produced using FSC

or PEFC certified paper, without, in some

cases, even fully understanding what they

were asking for! Thus, our natural next

step was to secure the Chain of Custody

Certificates for

both types of

papers. However,

even this was not

as simple as you

might expect.

Having obtained

the accreditation,

we still struggle to

purchase FSC material in the large format

size we require at a commercially viable

price.

At the same time,

we invited the Carbon

Trust to come and

conduct a carbon

survey on site. They

identified an 11-point

action plan for us to work through to

help reduce our carbon emissions and

energy usage and as a result, to help us

save money. These ranged from simply

making our employees aware of what

they could do to help prevent energy

wastage, to investing in different areas of

the factory to improve our energy control.

In line with this, we have also signed up to

the BPIF Climate Change Levy Umbrella

Agreement and achieved the four percent

savings set for the first year. Now, we are

looking forward to implementing further

improvements to achieve the 14 percent

reduction required for the next two years.

One of our training providers once said:

“ISO 14001 can be your best friend”. In 2008

we embarked on a journey to become

formally accredited with this standard.

Our EMS not only allows us to continually

develop, by constantly questioning why

we do things in a certain manner and

looking for improvements that affect both

our profitability and the environment, but

has also opened the doors to more clients

Over recent years we have noticed a greater drive from our clients, pushing more and

more for us to help them demonstrate green credentials, throughout their supply chains

GREEN PRINTERS


and prospects, who wish only to work with

suppliers, who seriously consider their

impact on the environment.

In driving environmental considerations

into our workforce we have offered them

NVQ Level 2 in Recycling and Waste

Management. We already segregated our

print substrates for recycling, for example:

paper, board, PVC, etc., but we have also

started to recycle the plastic shrink wrap

from both the goods in and despatch

functions of the business and, in addition to

this, the plastic strapping from the pallets.

Obsolete dyes had always caused issues

with their weight and bulk, quickly filling

the skips to go to landfill and adding to

the cost of waste removal. These are now

also recycled; removed from our site by a

licensed waste carrier and then processed

into chippings. Until recently, the revenue

generated from recycling has far and

above paid for the cost for any hazardous

waste removal or collection of waste to

landfill. But although we currently receive

no revenue (due to the current economic

climate), we still continue to recycle. And

it is not only waste from the factory floor

that can make a difference; we are also

diverting all plastic cups, aluminium cans,

plastic bottles, secondary cardboard food

packaging, toner cartridges and small

batteries away from landfill and into our

recycling streams, to ensure our volumes to

landfill stay on target and we continue to

have a positive impact on our surrounding

environment.


www.simpsongroup.co.uk

Now, we are looking forward to implementing further improvements to achieve the 14 percent reduction required for

the next two years

GREEN PRINTERS


Hamburg-based Emil Frey KG Siebdruck +

Schilder began its green journey by ensuring

safe working conditions for its employees. In

the first instance, it worked closely with other

screenprinters to encourage the Federal Institute

for Occupational Safety and Health (FIOSH) and the German

Printing Association (BVDM) to provide guidelines with regard to

employees’ exposure to toxic chemicals. All employees were then

regularly tested to ensure that the legal limits thus set were strictly

adhered to. At the same time, the company made the decision

to change to UV curable inks, wherever possible and installed

an automatic screen cleaning plant, which discharges only

ink-mud as waste and virtually no solvent effluence. In addition,

it began to use a much milder solvent for screen cleaning. As

a result pollution has now been reduced to such a low level

that employee testing is no longer necessary, which, as well as

being better for its staff, also reduces Emil Frey KG Siebdruck +

Schilder’s costs too.

The company also belongs to a local environmental

partnership, which stipulates that partners should be able

to demonstrate that they operate environmentally friendly

production processes. The partnership holds regular meetings

where partner companies can swap opinions and experiences

and also discuss ways in which to make the partnership more

effective.

Managing Director Hellmuth Frey states that he views

environmental compatibility not merely as a target but more as

a way of life. He says: “As far as the environment is concerned,

I don’t believe that you ever get to a point where you have

finished, because there is always more to be done.

“As long as there are greener materials, greener equipment

and more ecologically responsible ways of doing things, we will

continue to adapt and strive to make an even safer workplace

for our employees and greener products for our customers.” He

adds that both the national printing associations and FESPA are

a good source for fresh ideas and information and concludes:

“Our green quest will go on until we find the ultimate green

solutions and, since I feel that is still a long time away, our work

will continue!”

For further information visit: www.frey-siebdruck.de

First established in 1992, as a

sub-supplier to the sign trade,

Sign Services is now the

leading company of its type in

Denmark, where it remains the

premier choice of signmakers.

The company, which operates a strict

‘trade only’ policy, believes that there are

several reasons why we should all take

care of the planet. In the first instance, it

sets great store by providing a clean and

safe workplace for

its employees, but

equally important,

it feels, is the

responsibility it has for

both the environment and its customers,

who are facing a rising demand for

environmentally responsible production

and products. And last, but by no means

least, Sign Services has discovered that

being able to satisfy these demands

actually helps it to make money, a most

important consideration.

From the beginning, Sign Service

has always tried to offer its staff a

safe and congenial workplace, and

carefully monitors the equipment and

materials it uses and the impact they

have on the working

environment. Sign

Service’s Managing

Director, Benny Eriksen

comments: “In order

to meet our customers’ expectations we

need to have the best and most motivated

employees, and to make sure that we keep

them.

“Based on this philosophy, we have

chosen to change from using solvent

based inks to water based latex inks, and

we are currently studying all of the new

green substrates that we can find, to see

if they perform satisfactorily and whether

they are economically viable. Happily, this

change in printing methodology has had

another very positive outcome in that it has

opened up a new revenue stream for us in

the form of producing green products for

our clients.”

Benny Eriksen continues: “When we

are looking for new equipment today, one

of the things that we take into account

is its total impact upon the environment.

We look at its electrical consumption, the

need for ventilation, the amount of waste

in terms of ink and emissions and so on.

The list is growing and the biggest change

is that nowadays, we aren’t just looking at

the economic effects of waste; we need

to be able to reassure our clients that

their products have been produced in a

responsible way too.”

Benny goes on to say however, that

whilst clients now often stipulate that

products be made from ecologically

responsible materials , there is still a

limit as to how much they will pay. He

explains: “Whilst demanding greener

products, clients still expect the same

level of performance and quality, and in

order to achieve this we sometimes have

to charge a little more. Hopefully, we will

soon get to the point where what we are

offering is better, greener and cheaper

too, although it is a very hard nut to

crack! We have already gone through

this cycle with respect to our LED signs,

which combine superior illumination with

a much longer life

and greatly reduced

running costs. And

although the initial

investment is much

higher than for more traditional lighting

sources, our clients are beginning to

realise that over the full lifetime of the

sign, LED works out much cheaper. I am

hoping that, in time, substrate suppliers

will also come up with an original and

superior green material, rather than

simply providing substitutes for materials

that are in current use. When this

happens price won’t be quite the issue

that it is now.”

Benny also provides the best possible

reason for being green, when he says:

“Being able to

demonstrate that we

take green issues

seriously, gives us the

opportunity to really

stand out from the competition and to win

more work as a result – that’s what I regard

as a true win-win situation!”


www.sign-service.dk and www.giga.org

When we are looking for new equipment today, one of the things that we take into account

is its total impact upon the environment

Being able to demonstrate that we take green issues seriously, gives us the opportunity to

really stand out from the competition

GREEN PRINTERS


Located in Lenting, Germany,

the Stiefel Group Europe is an

international organisation

that comprises 16 associated

companies and employs over

300 people in eight different countries.

Taking as its ethos innovation, competence,

workmanship and customer proximity, the

company’s aim is to provide ‘Innovation in

Pictures’. Stiefel Digitalprint GmbH, which

is one of four separate Stiefel companies

operating in Germany, styles itself as

one of the most outstanding print service

providers of large format digital printing in

Germany and Austria. Established some 10

years ago, it boasts around 100 employees

and uses an impressive portfolio of 27

printers and finishing machines. The

company produces the full gamut of

printed products, such as banners,

building and vehicle wraps, floor graphics

and various printed textiles as well as

advertising material featuring map motifs,

using both rigid and flexible substrates.

Some months ago, in response to

its global customer base who were

demanding greener products, Stiefel

implemented its special Bioprint

programme. It had already experimented

by using different substrates with different

inks, with little success, until it saw some

examples of work produced using HP’s

Latex Ink Technology. Accordingly,

Stiefel was one of the first companies in

line to buy the new HP Designjet L65500,

which uses HP’s specially developed,

non-hazardous Latex ink, that, none the

less, still outputs arresting colours and

produces outdoor durable prints. Stiefel

also now uses PVC-free substrates, such

as polypropylene and various substrates

made from sustainable plant fibres. In

addition, it takes a much more proactive

approach when buying materials, by

keeping in touch with its current suppliers,

as well as continuously sourcing new

ones, so that it can be amongst the first to

trial new substrates as soon as they are

launched.

By offering a uniquely green production

concept which combines equipment, ink

and materials, Stiefel has attracted a lot

of new customers, although initially they

tend to be rather conservative. In order

to show them the full advantages of its

greener print methods, Stiefel produces

lots of samples to demonstrate quality and

durability. Almost to a man, clients are

impressed by the wide colour gamut and

high resolution that the L65500 offers and

Stiefel is impressed by the machine’s ease

of operation. Although HP offers an online

support facility to help ease companies

through any initial teething problems,

Stiefel reports that it was seldom necessary

to use it.

The company’s next step is to focus

on every aspect of its production to make

it more efficient and effective and in so

doing to reduce its energy consumption

and associated costs.

For further Information visit:

www.stiefel-online.com

By offering a uniquely green production concept, which combines equipment, ink and materials,

Stiefel has attracted a lot of new customers


GREEN CREDENTIALS

Many manufacturers and suppliers have already heeded end-users’ demands for more environmentally friendly products and as well as producing greener alternatives, they’ve streamlined their production processes, as detailed below.

Alcan takes a holistic approachKerstin Walter, Head of Marketing Strategy at ALCAN COMPOSITES Display Europe, explains the company’s green philosophy

Having some years ago recognised the growing desire amongst

print buyers for their print providers and material suppliers

to be able to demonstrate ecological responsibility, we have

developed a comprehensive ‘green’ philosophy. This has seen

us actively reduce environmental pollution, thanks to the careful

and more efficient use of resources, whilst also providing the

safest possible working conditions for our staff. In addition,

as a globally active enterprise, we have become an active

campaigner for sustainability, which we classify under three

separate areas: technological, social and economic.

Environmental management systemsFor quite some time, our three production sites in Germany and

Switzerland have been ISO 14001 accredited, and in the lead

up to our accreditation, we thoroughly overhauled all of our

internal practices and systems to ensure that environmental

issues are properly considered, both during daily tasks and

when corporate policy is being decided. More importantly,

we continue to set ourselves new targets and monitor our

performance by way of regular external audits. Since 2003, one

of our most challenging objectives has been to integrate the

workings of our quality (ISO 9001), environmental protection

(ISO 14001) and occupational safety (OHAS 18001) management

systems to ensure that that we are following the best and most

efficient practice in terms of safety, health and environmental

protection. By the same token, when selecting suppliers, we

always choose companies who are similarly ISO certificated

and who are able to demonstrate an appropriate level of

ecocological responsibility.

SubstancesIn the past few years, discussions about hazardous substances

have reached fever pitch and now suppliers ignore the

more exacting requirements of customers at their peril. A

comprehensive restructuring of European chemical policy is

now being implemented in line with the directives of the much

publicised REACH regulations, and consequently we are working

hard to eliminate all hazardous processes and to ensure that all

of the raw materials we use are harmless.

Accordingly, unlike some competing products, the lacquers

used in the manufacture of DIBOND do not contain any heavy

metals and the entire DIBOND manufacturing programme

has been tested and certificated by an independent

arbiter. Furthermore, our FOREX product family also meets

EU requirements regarding the restriction of hazardous

substances, such as lead, mercury, cadmium, chromium (VI), PBB

(polybrominated biphenyl) and PBDE (polybrominated diphenyl

ethers) and neither does it contain formaldehyde, FCKW, silicon

or softener.

Our KAPA product range uses papers with SFI, PE FC as well as

FSC certification, which underlines the fact that they are sourced

from sustainable forests and are low chlorine and oxygen

bleached, whilst the paper coating of our new FOAM-X material

comprises 100 percent recycled paper.

Waste reduction and recyclingWe have also arranged our production cycle so that it

can reduce waste and recycle the raw materials used in

our production processes. The recycling rate for our most

important raw materials is now virtually 100 percent. When

we manufacture FOREX, all of the cutting and trimming waste

is collected, according to variety, before being re-granulated

and reused without any apparent loss of quality. In the DIBOND

manufacturing cycle the aluminium sheets are separated, again

according to variety, and are processed for complete reuse.

In addition to comprehensive recycling during production,

our Alcan Singen factory is the only manufacturer that also

offers a recycling service for used DIBOND. Initially introduced

in Germany, our distributors within the UK are now also

operating this ‘take-back’ service and

we are hoping to eventually expand it

throughout Europe. We are also currently

determining whether KAPA waste can be

used to generate energy.

InnovationInnovation plays a key role in our efforts

to reduce environmental pollution. For

the most part, the popularity of our

DIBOND, FOREX and KAPA products

is due to the fact that they are ‘fit

for purpose’ whilst also conserving resources.

Now FOREXsmart, our latest generation of display substrates,

represents another step in the direction of resource efficiency,

since it combines excellent display qualities, including good

printability, high colour rendition and flatness, with good

mechanical properties, rigidity and an extremely low weight.

For example, with regard to dimensional stability, a 10 mm

FOREXsmart sheet is comparable to a solid extruded sheet with

a thickness of 6.7 mm, but as it weighs 70 percent less, handling,

installation and transportation are easier and cheaper.

More and more, ethically sound behaviour is becoming a

basic prerequisite for any business enterprise and at Alcan we

are fully aware of our responsibilities!

For further information visit: www.alcan.com/sustainability

y

rces

Alcan relies on sustainability and environmental protection Sustainability and environmental protection represent an increasingly important topic in advertising and visual communication. The increased environmental awareness and the demand for more sustainability are becoming essential criteria for buying decisions. Furthermore, in addition to the need for environmental compatibility, the demand for the company’s social and also overall economic involvement is increasing. Environmental protection as an integrative component of sustainability management at Alcan Sustainable involvement and the appurtenant sub-area environmental protection have long since been amongst the essential corporate objectives at Alcan. The minimisation of risks for man and environment as well as the reduction of environmental pollution through careful and efficient utilisation of resources is part of the corporate philosophy. Alcan is aware of its responsibility as a globally active enterprise, and has been an active campaigner in matters of sustainability for quite some time. Sustainability manage-ment at Alcan deals in depth with all three levels of sustainable action: the ecological, social and eco-nomic levels. In addition to concrete activities, Alcan endeavours towards transparent communication and seeks dialogue with all interest groups. Our responsibility for the environment: in the following fields of action we endeavour to implement the claim into practical reality! Environmental management systems For quite some time our three display production sites in Germany and Switzerland have been certified in accordance with ISO 14001, which establishes globally recognised requirements for environmental man-agement. Through this it is ensured that the environmental aspects will be taken into consideration with all daily tasks and corporate policy decisions. On the basis of uniform processes and structures we have hereby been able to anchor an environmentally appropriate behaviour in the company. We continually endeavour to improve our behaviour through regular external audits. ISO certification is also an important criterion in our selection of suppliers. Furthermore, a strong linkage of management systems for quality (ISO 9001), environmental protection (ISO 14001) and occupational safety (OHAS 18001) is an important objective for us. The environmental protection tasks will be more strongly integrated in the operative sequences in this manner. These industry standards are incorporated corporate-wide in a management system in the realm of safety-health-environmental protection. The programme called into being in 2003 as a self-obligation comprises

GREEN CREDENTIALS

Epson has initiated several green

strategies and there are more in the

pipeline.

Currently it is working to make its inks

as environmentally friendly as possible,

without sacrificing quality. For example,

for its GS6000 Stylus Pro printer, it has

developed the new Epson UltraChrome

GS, eight-colour eco-solvent type ink

set, which is available in efficient 950ml

cartridges. However, more importantly

for the environment and operators, it

doesn’t spread harmful VOCs and is the

first major eco-solvent type ink set to be

launched without the need for a hazard

symbol. This makes the GS6000 printer both

environmentally and user friendly and, as

there is no need for additional ventilation,

it can be located in the most convenient

spot. Furthermore, Epson has focused on

significantly reducing the need for time-

consuming daily operator maintenance,

thus increasing the machine’s productivity.

The Stylus Pro GS6000 is also the

company’s first LFP to come complete with

a recycling box for its spent ink cartridges.

The Epson Collect&Recycle initiative,

which has been running in Europe since

February 2006, has now become part

of the company’s Environmental Vision

2050 sustainability programme. Epson

operates a free box collection service

across Europe and South Africa for empty

cartridges for most of its printer range.

Customers from larger companies, who

tend to use cartridges relatively quickly,

can register online (www.epsoneurope.

com/environment/collectandrecycle) to

request a collection box, which is delivered

within five working days. When full, the

customer can request a pick-up and a

replacement box if required.

100 percent of the cartridges collected

through the scheme are recycled:

their plastic components are reused in

manufacturing and construction, while

metal parts are smelted and reused in

other industrial applications.

www.epson.co.uk/environment/

Eco_Brochure.pdf and

www.env.epson-europe.com/

In 2004 Kornit decided to invest in the

development of green products, especially

inks, even though this required significant

funding, much creativity and a lot of

effort in relation to the development of

greener solutions. The company’s green

ideology began with the provision of an

eco friendly work environment and the

careful selection of outsourced contractors,

as Kornit will not now accept any product

or service from contractors that don’t meet

its own exacting environmental standards.

One of its major challenges lay in

changing the ink chemistry that underpins

the whole garment printing process, as

previously, this has involved various toxic

materials, in order to achieve the optimum

printing results clients demanded.

Another equally difficult challenge

has been the education of the market.

Kornit has found that it is not always easy

to persuade a perfectly satisfied customer

to completely change his production line,

especially when there’s no proof that he’ll

also be increasing his profitability!

However, in 2006 Kornit launched its

own line of CMYK water based inks, which it

has been promoting ever since and which

achieve the balance between eco friendly

components and optimum compatibility

and printing performance, when used in

conjunction with a Kornit printer. The inks

successfully meet the California standards

for green products, being alkylphenol

ethoxylates (APE) free, lead free, chromium

free and cadmium free.

In addition, Kornit has also developed

its own 100 percent environmentally

friendly pre-treatment wetting solution.

Combining water with wetting additives,

it is automatically applied directly on

to the area of the garment that is to be

printed, where it prepares the surface for

the application of Kornit’s special textile

inks. During the heat-curing process, the

two generate a chemical reaction that

binds the ink to the garment’s fibres. At

this point, the wetting solution evaporates

safely into the atmosphere, and the result

is a four-colour process image, which

features excellent colour density and an

exceptional colour gamut.

In order to ensure the consistency of

its green manufacturing processes, the

Kornit ink factory goes through periodic

evaluations by independent arbiters.


www.kornit-digital.com



GREEN CREDENTIALS

Despite the fact that the front-end

chemistry involved in the production

of graphic films proves a stumbling

block to eco friendly disposal of excess

or redundant products, Kay Premium

Marking Films certainly recognises its

responsibility to protect the local and the

global environment from any operational

risks and impacts posed at its South

Wales site. The company, which is ISO

14001accredited, upholds the view that

sensitive manufacturing policies can

play a big part in minimising the threat to

our planet, with KPMF Quality Manager,

Rob Musto, quoting from a notice that

he saw in an Egyptian hotel regarding

the laundry of guest’s towels: ‘We did not

inherit the earth from our parents, we are

merely borrowing it from our children’.

Rob subscribes wholeheartedly to

this principle and is proud that, over the

last financial year, KPMF has diverted

52 tonnes of waste, comprising mainly

packaging, polyethylene, pick hoses,

pallet or wood waste, cardboard and

waste pick, from landfill sites. In addition,

reports are submitted annually to the

local authority reporting emissions to

atmosphere. Measurements are taken via

a sampling point on the chimney of KPMF’s

recuperative thermal oxidiser.

The KPMF management team assesses

all aspects of production for the impact

they cause and as such, significant

Staedtler – the ecological pioneerWolfgang Pöhlau, Director Business Unit Ink Jet at STAEDTLER Mars GmbH explains how the development of the company’s Lumocolor Jet Ink came about.

“Imagine this: It is winter; children are building igloos and

throwing snowballs at each other. Adults are skiing on a thick

layer of ice-cold powder snow. Fantastic, isn’t it?

Well, this is how winter used to be when I was a child, some

30 years ago. We had a wonderful time shuffling snow around,

even at only 300 metres altitude. Nowadays, it is getting harder

to find some snow for skiing in the lower lying valleys of the Alps.

And if the forecasts of the climate experts are correct, we will

only be able to tell our children what winter used to be, ‘once

upon a time’. So there is no doubt that preventing an even more

dramatic climate change is the most important issue to be solved

by mankind.

‘We have to do something!’ This is what Staedtler Ink Jet’s

engineers thought when they started the development of the first

water based inks for printing on to nearly all materials, back in

2002. With over 170 years of company history, Staedtler is a truly

long-term oriented company, so environmental protection has

always been one of its top priorities.

When the first ink prototype was presented to the public in

2004, the working title, Lumocolor Jet ink was chosen, due to its

similar characteristics to Staedtler’s top-selling Lumocolor pen,

which enables the user to write on almost every surface.

Lumocolor pen – STAEDTLER’s top-seller

Although our intention was to be the trendsetter for a more

environmentally friendly future, we could not anticipate that this

ink technology would transform the mindset of the entire industry

in such a profound way. But Lumocolor Jet ink technology was

indeed a revolution, since we had proven that it is no utopia

to develop water based inks capable of doing the ‘heavy jobs’.

Today, even big companies are promoting water based inks with

similar characteristics and we are justifiably very proud to have

started the ‘ecological movement’ within the inkjet industry.

As a technological pioneer, we faced, on the one hand,

the burden of heavy development costs, from which followers

would benefit. On the other hand, we can now use our know-

how to adapt the technology for more and more applications,

even those that could not be served by any kind of ink before.

Consequently, the Lumocolor Jet ink technology is nowadays

used mostly in the area of industrial applications, such as

furniture decoration and similar.

With this innovation, we have established ourselves as one

of the best known inkjet ink manufacturers worldwide and

as the specialists for water based inks in the field of industrial

decoration.

Lumocolor Jet ink technology for industrial decoration

In fact, the Lumocolor Jet ink technology with its impact

on the industry is the latest step in our major ecological

developments, which include multi-use cartridges, or ink bags,

that dramatically reduce the amount of waste. We will continue

to take our responsibilities as a pioneer in environmental

protection very seriously and we invite you to guess what we will

introduce next!”

For further information visit: www.staedtler-inkjet.com

preventive measures have been introduced. A distillation unit

was installed to recover solvent used for cleaning at the factory;

Lux meters measure light within the building and when the light

is sufficient for the operators, any internal lighting automatically

switches off. The company is even investigating the generation of

a virtually paperless office environment, by making all documents

accessible, throughout the Company, from a central location

stored on the main computer server.

Any rejected rolls of coloured vinyls are donated to local

schools and community groups for use in creating artwork or

generating costumes for carnivals and theatrical productions.

KPMF constantly reviews current and forthcoming changes

to legislation to determine the measures and methods that

allow it to retain the highest standards of compliance. As Rob

Musto says: “As a company, we try always to be proactive not

reactive. By constant assessment of all aspects, we ensure that

our environmental management makes a major contribution to

our quality control – and that’s good for the bottom line, as well

as the planet.”

For further information visit: www.kpmf.com

Xaar takes an environmentally responsible approach to the

manufacture of its printheads. “Having achieved ISO 14001

status, we take clean manufacturing very seriously,” says Mark

Alexander, Director of Marketing, “and our focus is on effective

waste recycling.” Metal, plastics, glass and paper are all recycled,

while methods of removing PZT in scrap printheads are currently

being investigated. The use of solvents is closely monitored and

collected solvent is recycled as a high-octane fuel for producing

cement.

From Xaar’s customers’ point of view, efficiency is built into Xaar

inkjet printheads as a key element of their design and this, in turn,

maximises their environmental credentials. The latest Xaar 1001,

for example, cuts ink waste by using a very small amount to purge

and re-circulates ink instead of spitting when idle. “These are

small elements but quickly make a difference in terms of cutting

costs and waste,” explains Mark Alexander. “Energy saving too is

a factor. Printheads are low energy/high efficiency components,

which is becoming increasingly significant.”

Ultimately, when compared to traditional process of off set/flexo

printing, inkjet printing is a ‘greener’ process. Start up waste paper

is minimal, there are no plates or blankets to be disposed of or

cleaned and you can print exactly what you need ‘to order’.

For further information visit: www.xaar.co.uk

Roland DG Benelux has taken further steps towards making its

operations more ecologically responsible with the launch of a

new cartridge recycling scheme. Some years ago, Roland DG

Corporation set out several basic ecological principles. One of

these was the development of products comprising recyclable

parts. An optimal result was achieved in this regard, with the

launch of the SP range of large format printers, which feature

parts that are 97 percent recyclable.

In 2007, Roland DG Corporation introduced its own

Environmental Label based on the standards stipulated by ISO

14021 for Type II environmental labelling. This certifies that the

company helps to prevent global warming by using recylable

resources, helping to increase environmental awareness and

providing information on the environmental aspects of its products.

All products released after the introduction of the Eco-

Label are built in accordance with these internal standards.

Durable indoor and outdoor prints on coated & uncoated substrates up to 1625 mm (63.97”) wide

Impeccable print quality every time with Mutoh new i2 technology, even with the most difficult images

Rapid return on investment thanks to versatile performance and attractive price

Easy to use and compact, with Eco-Sol-vent Ultra inks for problem-free printing in normal environments

Print speeds up to 18.25 m2 per hour

www.mutoh.euwww.mutoh.de

A versatile high resolution printer for durable graphics

A versatile high resolution printer for durable graphics

1614


GREEN CREDENTIALS

Moreover, all recently released products

(including the VP and AJ printer series)

meet the criteria of Energy Star. This is a

joint program of the U.S. Environmental

Protection Agency and the U.S. Department

of Energy, which helps to save money

and protect the environment through

energy efficient products and practices.

The Energy Star ensures that the certified

Roland products are built to an optimal

performance/energy ratio.

At the end of last year, Roland DG

Corporation made another step to promote

a more environmentally friendly future.

It centralised all of its production in one

plant in Miyakoda, Japan, which enabled

it to further reduce the ecological footprint

of its products, as the time and resources

involved in transporting parts between

external warehouses and the factory was

eliminated. Furthermore, Roland DG’s

D-Shop technology – an automated cell-

based model, where a single employee

assembles a product from start to finish,

enables the company to carefully control

the production time of its products and

thus considerably reduce its energy

consumption. As a result of these measures,

Roland DG is aiming to reduce its carbon

dioxide emissions by a total of 40 tons per

year.

FESPA Digital 2009 will be the starting

point for another important initiative,

the launch of a closed-circle recycling

programme. Following the example of

Roland DG Corporation in Japan, Roland

DG Benelux will implement a cartridge

recycling programme. The residue of

recycled cartridges will be used as raw

materials for new products.


www.rolanddg.be

Marabu – the Green Ink PioneerIn recent years, environmental thinking

and sustainability have become important

aspects of all business activities. As a

leading ink manufacturer, Marabu well

understands the responsibility it has for

ensuring that neither human health nor

the environment is adversely affected by

its activities. Through investments in the

latest technology and the responsible

use of energy and raw materials, it seeks

to minimise the environmental impact

associated with its plant.

The company, which actively

participates in several working groups

looking at sustainability, first appointed an

Environmental Manager in 1990, to work

within its quality assurance department,

but its green credentials stretch back

much further. Originally established to

manufacture artists’ paints and inks,

Marabu celebrates its 150th anniversary

this year, and, for some considerable

time, it has operated strict environmental

policies regarding waste disposal, energy

use, smart ink management systems,

packaging, recycling, and its core ink

formulation. During the manufacturing

process, all solvent emissions are filtered,

cleaning solvents are recycled, with up to

95 percent being reused, whilst all water is

treated. Another major step forward took

place two years ago, when Marabu began

using renewable power, thus reducing its

annual C02 carbon emissions by 2,300 tons

annually.

To minimise its waste, all packaging

materials are chosen for their recyclability

and volume products are offered in

230 kg in-lined drums, and supplied with

a corresponding drum dispensing unit.

In addition, Smart Colour management

systems enable ink customers to specify

precise quantities of special shades,

thus avoiding unusable excess. Marabu

also implemented its own stringent raw

material protocol in 1994, when it became

the first screen and pad printing ink

manufacturer to exclude heavy-metal

pigments from its products. It is now

compliant with EuPIA’s exclusion list for

printing inks and related products.

The company has achieved many

accreditations and received many

awards for its green manufacturing

processes and products. Following its

initial ISO 9001 certification in early 1995,

it included many green practices in its

quality assurance systems, achieving the

ISO 14001 certification for Environmental

Management in 2003. In the same year, it

gained SONY Green Partner certification, in

respect of its inks for optical disc production,

a certification that has been renewed

annually. In 2004 it was awarded the SGIA’s

Environmental Achievement Award.

It originally introduced environmental

awareness into its screen and pad ink

with the creation of LIBRA, a solvent screen

ink family, which used a combination of

mild solvents, thus resulting in greater

benefits for both the environment and

machine operators. The LIBRA family of

products was first launched in 1985 with

Libragloss LIG, a universal ink for every-

day screenprinting jobs. Its mild odour,

combined with excellent performance

was enthusiastically received and in 1993,

Libraspeed LIS, which was designed to suit

the more automated screen machinery

introduced during that period, followed

it. The Libramatt LIM series, introduced

in 1997, fulfilled the need for a matt ink

series and in 1999, Libraprint LIP reflected

the increasing need for speed, by offering

faster drying times. Last year the LIBRA

family expanded once again, with the

launch of Librastar HF, for industrial print

applications.

Librastar HF is the first ink to meet

the demands of the electronics sector

and incorporates halogen-free raw

materials, such as a PVC-free binder and

unchlorinated pigments. It is suitable for

use with both screen and pad printing and

for one or two component applications.

Marabu is fully sensible of the need to

combine environmental benefits with high

performance for demanding applications

KALA SAS - 35410 Nouvoitou-France / Tél. : +33 (0)2 99 37 64 64Web site : www.kala.fr / Information & contact : [email protected]

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GREEN CREDENTIALS

and Librastar HF fulfils both of these

aspects. It corresponds to the demands of

RoHs; the Canadian Hazardous Products

Act, DIN EN 71/3 and sets the benchmark

for halogen-free ink design. Another new

UV ink, Ultraglass UVGCC was recently

showcased at the new Nutec Exhibition

in Frankfurt and was also accepted by

Material ConneXion®(materialconnexion.

com), the leading global platform for

material solutions and innovations.


www.marabu-inks.com

As one of the leading providers in the

graphics sector, Neschen recognised the

trend towards greater green awareness

some time ago and consistently uses green

production processes and materials.

For example, its Pro Nature product,

which is subjected to the most stringent

internal norms and checks, is a

result of this, but as Neschen’s Frank

Seemann, Head of the Marketing and

Communications Department at Neschen

AG in Bückeburg, Germany points out:

“ Pro Nature is not just a label for the

customer – the advertising materials

for this line are made exclusively of

environmentally and resource-friendly

materials. One of these is cotton – a natural

fibre that is not just pleasantly warm and

soft, but also kind to the skin. So it goes

without saying that cotton is becoming

more and more popular, particularly in

interior graphic design”.

Corn is another new trend. As a result,

Neschen also offers digital print media that

is made entirely of cornstarch. Printed with

eco inks – also made from cornstarch – this

combination provides environmentally

friendly advertising materials that are also

completely biodegradable.

Since both corn and cotton are

renewable natural materials, no finite

fossil fuels are required. But even synthetic

materials or plastics that are usually

manufactured from oil can be produced

sustainably. One example is the polyolefin

group (PO). These include several well-

known materials, such as polypropylene

(PP), which Neschen uses as a basic

material in banner production.

The material used to make PP is a by-

product of the petroleum industry, which

is generated each day in the refineries

and is also used in the food industry.

During combustion of the raw material or

the PP film, only water (H2O) and carbon

dioxide (CO2) are emitted as reaction

products. No other hazardous by-products

are generated and modern cleaning

and filter systems also further minimise

emissions. This is a key difference when

PP is compared to the majority of other

synthetics and plastics that have to be

specially disposed of and are often very

harmful to the environment.

In addition to maintaining quality,

Neschen is keen to save energy. As a result,

it has fitted its own water filtering system

that, after thorough purification, feeds the

water from film production back into the

public water supply. This revolutionary

system decreases water consumption by

several thousand cubic metres annually.

Further, the company has implemented

a highly efficient energy recovery system

that has reduced the consumption of its

manufacturing machinery to a minimum.

Frank Seemann comments: “In the final

analysis, Neschen is not just a product

trendsetter in its markets. It has also

been a green pioneer and its continuing

commitment to top-level research and

development will ensure it continues to

break new ground in the future.”


www.neschen.de

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Documents

FESPA WORLD Issue 54 (Part 2) - English