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Sustainable Platemaking 2011 Update

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Sustainable Platemaking 2011 Update Ray Bodwell Agenda Recap - Sustainability Pressures Across Value Chain DuPont & Sustainability Cyrel and Sustainability TR3 ... – PowerPoint PPT presentation

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Title: Sustainable Platemaking 2011 Update


1
Sustainable Platemaking2011 Update
Ray Bodwell
2
Agenda
  • Recap - Sustainability Pressures Across Value
    Chain
  • DuPont Sustainability
  • Cyrel and Sustainability
  • TR3 Return, Reuse, Recycle

3
Drivers Across the Value Chain
The Original Push Wal-Mart 7Rs Scorecard
  • 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)

7 Rs 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).
4
Drivers Across the Value Chain
5
(No Transcript)
6
Global Drivers
Drivers Across the Value Chain
EUROPEN The European Organization for Packaging
and the Environment
Its no longer a question of whether or not
EPR will come to America its only a question of
when and on whose terms. Julian Carroll, EUROPEN
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.
  • 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.
  • Sustainability Consortium
  • Administered by Arizona State U. of Arkansas
  • Cradle to grave view of products packaging
  • Global Index

7
Sustainable Packaging Coalition
Drivers Across the Value Chain
Clean Production Technologies
Material Use
Water Use
Community Impact
Energy Use
Worker Impact
Cost Performance
Material Health
SPC Definition of Sustainable Packaging
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
8
Drivers Across the Value Chain
Greening the Supply Chain
Logistics
Sourcing
?
Carbon Footprint Strategy
?
Waste Disposal
?
Packaging / Product Design
?
9
DuPont Sustainability
DuPont Mission Sustainable Growth
  • The creation of shareholder and societal value
    while we reduce the environmental footprint
    along the value chains in which we operate.

DuPont defines footprint as all injuries,
illnesses, incidents, waste, emissions, use of
water and depletable forms of raw materials and
energy.
10
DuPont Scorecard Systems Thinking - 2006
DuPont Sustainability
Downstream Assessment Criteria
  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.

11
We Do Take Actually It Seriously
12
DuPont Life Cycle Analysis
DuPont LCAs
  • 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)

13
Definition Life Cycle Assessment (LCA)
DuPont Life Cycle Analysis
  • 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

14
Results
DuPont Life Cycle Analysis
  • data from 2006-2007
  • publication in September 2008

1st step Original LCA
2nd step Update
  • data from 2009-2010
  • publication in April 2010
  • 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.

15
Original LCA Flexography vs. Rotogravure
DuPont Life Cycle Analysis
  • Flexography
  • Higher viscosity inks reduces solvent use
  • Reduced energy emissions for drying
  • Reduced substrate waste

Greenhouse Gas Emissions (kg CO 2 e per m2 of
product)
Non-Renewable Energy Use (MJ per m2 of product)
Aligned Plastic Substrate Model
16
Estimated Savings Flexography vs. Gravure
DuPont Life Cycle Analysis
Changing 10 Million ft2 of Printed Substrate from
Gravure to Flexographic Printing
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
Data Source http//www.usctcgateway.net/tool/
Based on DuPont Life Cycle Assessment
17
DuPont Life Cycle Analysis
Plate Processing Workflows
Total Production Time 2.5 4.0 hours
Total Production Time 30 45 mins.
18
Average Digital Flexographic Plate Imaging Impact
DuPont Life Cycle Analysis
With DR 44 fiberweb
19
Updated LCA Results Solvent vs.. Thermal
DuPont Life Cycle Analysis
Digital thermal 63 lower energy 53 lower
ghg vs. solvent
Figure 1 Average Digital Flexographic Plate
Imaging Impact
20
Estimated Savings Solvent-free System
DuPont Life Cycle Analysis
Changing 100,000 ft2 of Digital Flexo Plates from
Solvent Processing to Cyrel FAST Thermal System
  • 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

Data Source http//www.usctcgateway.net/tool/
Based on DuPont Life Cycle Assessment
21
DuPont Life Cycle Analysis
Source Reductions through Down-gauging
  • Down-gauging
  • Reduces overall footprint
  • Reduces drying time
  • Reduces solvent use recycling
  • Reduces energy consumption greenhouse gases

Greenhouse Gas Emissions kg eq.CO2 / ft2
Non renewable Energy Consumption (MJ/ft2)
  • Other benefits
  • Less board strength losses
  • Improved graphics
  • Supply chain reductions

Based on DuPont Life Cycle Assessment Study
22
Does This Really Matter?
DuPont Life Cycle Analysis
  • Yes Gravure vs. Flexo is meaningful and should
    matter to Wal-Mart
  • Yes Thermal vs. solvent also impactful over
    time, volume and multiple SKUs
  • Yes Down gauging plates has a measureable
    energy and CO2 savings that can also be
    impactful over time, volume and multiple SKUs

What about liquid and water wash plates?
  • We dont make them so we didnt measure them
  • All questions about energy and carbon footprint
    apply
  • Follow ISO 14040 Guidelines
  • Key questions around water consumption and waste
    water generation

23
Liquid 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!!

24
Wal-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 dont have access to
clean water and 2.5 billion lack proper sewage
and sanitation. According to estimates, demand
for freshwater will exceed the worlds 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?
25
Water Considerations Aging infrastructure,
climate change, strained city budgets
DuPont Life Cycle Analysis
RI Considers Raising Water Bills to Protect
Supply By THE ASSOCIATED PRESS Published
October 5, 2009
Associated Press February 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.
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.
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
26
Waste The Goal is Zero
But its not just about plate processing
Goal Expand and develop suitable recovery,
reuse or recycling options for all Plant waste
everything that we ship to Customers
TODAY
  • PACKAGING Waste e.g. polystyrene, gaylords,
    foam
  • PLATE Waste Plates, Trim,
  • CONSUMABLES butt rolls, base cover sheets,
    Binders, Polymers

27
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

28
DuPont TR3
  • DuPont 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)

29
Recycling Challenges Who to partner with?
DuPont TR3
  • 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
  • Weve 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

30
DuPont TR3
Recycling 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

31
DuPont TR3
TR3 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 wheres the catch?
32
Polymer Separation Requirements
DuPont TR3
  • 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

33
DuPont TR3
Box 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

34
DuPont TR3
Program Status
  • In external evaluation gt 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

35
Additional Resources
36
Resources Sustainability Best Practices
raymond.w.bodwell_at_usa.dupont.com
37
Resources DuPont LCA Reports
raymond.w.bodwell_at_usa.dupont.com
38
Resources
raymond.w.bodwell_at_usa.dupont.com
39
Thank you!
raymond.w.bodwell_at_usa.dupont.com
40
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