"Eco-conscious design" for printed matters

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

“Eco-conscious design” for printed products
Multilateral approaches for printing to go greener

Dr. SHIMIZU, Hirokazu
President, SHIMIZU PRINTING INC.
Visiting Senior Researcher, Waseda University Environmental Research Institute
Expert, ISO130 (Graphic technology) WG11(Environmental impact of graphic technology)

1

Waseda University Environmental Research Institute

Self-introduction “처음 뵙겠어요”
1. Date of birth
• May 19th, 1967
2. Qualification
• Specialist on UV printing technology of graphic arts
• Specialist on Life-cycle approach (LCA, LCC, MFCA..and etc.)
3. Pioneering achievements
• Development of “UV Waterless High-Definition” printing method
• Schematization of “Printing service LCA and LCCO2”
4. Award
• “UV Waterless High-definition” printing, Encouraging Prize by
Japanese Society of Printing Science and Technology in 2011
• “Establishment of quantitative assessment for printing service”,
Best Paper Award by Japanese Society of Printing Science and
Technology in 2010
• “Establishment of Printing service LCA to propose environment-
conscious solution”, Chairman’s Award (2nd best)
by 6th LCA Japan Forum in 2010
Shimizu Printing Inc. 2


Self-introduction “반갑습니다”
5. Extra activities (present)
• Visiting Senior Researcher, Waseda University Environmental
Research Institute (早稲田大学環境総合研究センター)
• Expert (Thailand), ISO130 (Graphic technology) WG11
(Environmental impact assessment of graphic technology)
• Policy Adviser for SMEs at Japan Chamber of Commerce
• Committee, Energy and Nuclear Committee at Japan Chamber
of Commerce
• Committee, Environment Committee at Tokyo Chamber of
Commerce
• Supervisor, Joint research project for CFP of printed products
with Chulalongkorn University in Thailand
6. Extra activities (past)
• Committee, Renewable energy buy-out committee at Ministry of
Economy, Trade and Industry
• Committee, Product Category Rule for Carbon Footprint of
Products Committee at Japan Federation of Printing Industry


Self-introduction “잘 부탁드립니다”
7. Academic paper
1) Hirokazu Shimizu, Katsuya Nagata, and Aran Hansuebsai. 2012. Comparisons of
Paper-‐‑‒book and E-‐‑‒book by the scale of carbon footprint. Proceedings of The Asian
Symposium on Printing Technology: 39-‐‑‒44
2) Hirokazu Shimizu, Katsuya Nagata, and Aran Hansuebsai. 2011. Integrated Life
cycle Assessment (LCA) for Printing Service in an emerging country. Proceedings
of EcoDesign 2011 International Symposium: 283-‐‑‒288
3) Hirokazu Shimizu, and Katsuya Nagata. 2010. Integrated Life cycle Assessment
(LCA) Approach for Printing Service by Using Environmental Load Point (ELP)
Method. Journal of Printing Science and Technology 47 (3): 39-‐‑‒47
4) Hirokazu Shimizu, and Katsuya Nagata. 2010. Comparison of Life-‐‑‒cycle CO2
emissions for Paper-‐‑‒Based Books and Electronic Books. Journal of Printing Science
and Technology 47 (2): 19-‐‑‒29
5) Hirokazu Shimizu. 2009. Establishment of quantitative assessment for Printing
Service. Journal of Printing Science and Technology 46 (6): 26-‐‑‒35



Agenda
1. Improving printed products to be “Eco-conscious” by quantitative
method, not by qualitative method
• Definition of Eco-conscious products
• Case study of plastic document file for Eco Product 2012
• New idea to promote printed products
2. Reforming current calculation standard (Product Category Rule)
to be wide-spread for SMEs
• Promotion of new calculation standard for printing
• Accuracy of existing calculation standard for printing
• Magnitude of calculation accuracy for new/existing standards
3. Utilizing “Printing Goes Green CLOUD (PGG-CLOUD)” to quantify
environmental impact by the scale of CO2
• Primary data and secondary data collection
• Actual operation
• Next step to evaluate by different impact categories



1. Eco-conscious printed products

Deﬁnition of Eco-conscious printed products:
The printed products which have “shining-
star quality” in terms of environment related
issues backed by quantitative assessment
(not by touchy-feely opinion, but by
numerical numbers)



1. Eco-conscious printed products (cont’d)
Case study: Polypropylene-made document ﬁle
Use application: Ad. tool for Eco Products 2012
Copies: 2000
Material: Polypropylene
Press: Bk+C+M+Y+W+Bk+C+M+Y+OP varnish
Post-press: Die-cut, glue
Normal practice: PP 0.20mm is used
Best practice: PP 0.15mm is used

How much can “Best practice” be improved
by by the scale of CO2 emission?


PP 0.20mm thickness PP 0.15mm thickness
m m Δ=PP0.15-PP0.20
5
# Item
kg-CO2e % kg-CO2e % kg-CO2e Δ％

1 Substrate 220.345 44.8% 165.259 39.3% -55.086 -25.0%
2 Ink & varnish 7.607 1.5% 7.607 1.8% - -

3 Printing plate 62.913 12.8% 62.913 15.0% - -

4 Additives 0.090 0.0% 0.090 0.0% - -
5 Other materials 1.291 0.3% 1.291 0.3% - -
6 Design/Editing 15.581 3.2% 15.581 3.7% - -

7 CtP 9.516 1.9% 9.516 2.3% - -
8 Press 79.002 16.1% 79.002 18.8% - -
9 Postpress 22.813 4.6% 22.813 5.4% - -
10 Water 0.000 0.0% 0.000 0.0% - -

11 Delivery 4.660 0.9% 4.414 1.1% -0.246 -5.3%
12 Waste from household and factory 67.280 13.7% 51.120 12.2% -16.160 -24.0%
13 Recycle from household 0.000 0.0% 0.000 0.0% - -
14 Recycle from factory 0.945 0.2% 0.756 0.2% -0.189 -20.0%
Total 492.043 100.0% 420.363 100.0% -71.680 -14.6%
Per copy 0.246 0.210



kg-CO2e
500
Recycle from f
-14.6% Recycle from h
Waste from h&f
Delivery
375 Water
Postpress
Press
CtP
250
Design/Editing
Other materials
Additives
125
Printing plate
Ink
PP 0.20mm Substrate
0
Shimizu Printing Inc.
PP 0.15mm 9


New idea to promote Eco-conscious printed products
-20%

D A AA AAA
Economical factor (¥)

-15%

D B A AA
-10%

D C B A
-5%

D D D D
-5% -10% -15% -20%
Environmental factor (CO2)


2. Reforming current PCR
Select only 10-item for simpliﬁcation
(1)Substrate NOT calculated
5% cut-oﬀ rule/Guess-work for primary data
(2)Transportation for substrate
(3)Ink & varnish Water (dampening solution)
Additive (dampening solution)
(4)Transportation for Ink & varnish
(5)Plate (waterless printing)
(6)Transportation for Plate
Prepress(editing, designing, CtP)
(7)Printing process (waterless printing)
(8)Post-press process
Material (glue, stitch...)
(9)Distribution
Wrapping material for delivery
(10)Waste & Recycle


2. Reforming current PCR (cont’d)
Points of modifying current PCR
I. Calculation method is standardized to “cumulative”

II. Modeling 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


1.Substrate (paper/plastic)

2. Trans. for Substrate (trucks/rail/surface/air)

Raw material acquisition

3.Ink & varnish (conv./UV ink, OP varnish, Coating varnish)

4.Trans. for Ink & varnish (trucks/rail/surface/air)

5.Plate (for waterless printing)

13
Points of modifying current PCR

6.Trans. for Plate (trucks/rail/surface/air)

7.Printing process (electricity for machines, lighting, air-cond.)
Production

8.Postpress process (electricity for machines, lighting, air-cond.)

9.Delivery (excluding packing materials)
Distribution

10.Waste from household, Recycle from factory and household
Waste/

Recycle


Accuracy of new PCR for Printing by case studies (Paper package for DVD)
100000 copies
0 30000 copies 10000 copies 5000 copies
c 500 copies
c
# Item
kg-CO2e % kg-CO2e % kg-CO2e % kg-CO2e % kg-CO2e %

1 Substrate 2104.4 69.6 701.4 64.3 300.6 58.5 200.4 52.5 110.2 41.6

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

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

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

5 Plate 36.2 1.2 36.2 3.3 36.2 7.0 36.2 9.5 36.2 13.7

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

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

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

9 Delivery 25.9 1.0 11.4 1.0 3.8 0.7 1.9 0.5 0.2 0.1

10 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 -



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

100%
Others
Waste & Recycle
Delivery
75% Postpress process
Printing process
Trans. for Plate
50% Plate
Trans. for Ink&varnish
Ink&varnish
25% Trans. for Subs.
Substrate
100000
30000
10000
5000 0%
Shimizu Printing Inc. 500 15


Accuracy of new PCR for Printing by case studies (Flyer from 300-500,000)
other items 10 items %
100

90

80

70

60

50
40

30

300
20
500
1000

10
1000
2000
2000
3300
5000
5000

0
5000
10000
10000
10000
10000
15000
20000
30000
Shimizu Printing Inc. 16 500000


Accuracy of new PCR for Printing by case studies (Booklet from 410-500,000)
other items 10 items %
100

90

80

70

60

50

40

30

20
410
500
1000

10
1300
2000
2000
2400
2700
4000
4500
5000
0
5000
9500
10000
10000
18000
18000
30000

50000
17 100000


Conclusion of new PCR accuracy
Carbon calc. by 10-selected item
Package
1.7% ～ 18.5% of “Others” by Shimizu Printing
Flyer
2.8% ～ 22.6% of “Others” by 18 cases (JWPA)
Booklet
0.8% ～ 32.2% of “Others” by 60 cases (JWPA)

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

Current PCR can provide absolute carbon calc. result?


Current PCR: The diﬀerence by emission factor 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.?

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



The diﬀerence by EF of paper (Magazine, 4000 copies)
kg-CO2e
+7.1% 2250 Recycle
Waste
2000 Delivery
-21.5%
Water
1750
1384.94 1541.192 Postpress
1500 Press
CtP
1250
Design/Editing
1000
913.137
Additives
750
Plate
Avg. E.F. 500 Ink
Max. E.F. 250 Paper
0
Shimizu Printing Inc. Min. E.F. 20


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?



The diﬀerence by calc. method (Paper package for DVD)
Cumulative Allocation % (Allocation/
Copies
g-CO2e/copy g-CO2e/copy Cumulative)
1000 276.075 223.708 81.0
2500 126.353 113.372 89.7
5000 76.362 71.132 93.2
7500 59.739 59.276 99.2
10000 51.398 53.349 103.8
20000 41.328 44.457 107.6
30000 36.359 41.493 114.1
40000 33.880 40.011 118.1
50000 32.389 39.122 120.8
60000 32.199 38.530 119.7
70000 31.375 38.106 121.5
80000 31.291 37.789 120.8
90000 30.811 37.542 121.8
100000 30.254 37.344 123.4


The diﬀerence by calc. method (Paper package for DVD)
300

250

200
Cumulative Allocation
150

100

50

0
1000 2500 5000 7500 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000



Conclusion of current PCR accuracy
Carbon calc. by diﬀerent EFs
+7.1% ～ -21.5% compared to avg. data
Carbon calc. by diﬀerent calc. methods
+23.4% ～ -19.0% compared to cumulative method

Current PCR has certain range of carbon calc. result

No absolute number from carbon calculation



Magnitude of ﬂuctuation by new/current PCR
Min. Max. %
Current PCR 130

123.4

97.2 107.1
99.2
97.5
77.4

78.5
67.8 81
65

32.5
10-item(ﬂyer)
10-item(Booklet)
Paper EF 0
Allo./Cum.


CFP trial (16-page booklet, 2000 copies) by 7-printer from JWPA
Item Shimizu A B C D E F

Material 2.90E-01 2.90E-01 2.90E-01 2.80E-01 2.80E-01 2.90E-01 2.80E-01

Production 6.80E-02 7.30E-02 8.50E-02 3.10E-02 2.40E-02 4.10E-02 3.10E-02

Delivery 3.30E-02 3.30E-02 3.30E-02 3.30E-02 3.40E-02 3.40E-02 3.30E-02

Use 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00

Disposal/Recycle 1.30E-02 1.00E-02 1.00E-02 1.20E-02 1.30E-02 1.30E-02 1.20E-02

TTL (kg-CO2e/copy) 4.00E-01 4.06E-01 4.18E-01 3.60E-01 3.50E-01 3.80E-01 3.60E-01

% comparison in group - 98.5% 101.5% 100.0% 97.2% 104.9% 100.0%

Avg. in group
4.00E-01 4.12E-01
E 3.60E-01
E
(kg-CO2e/copy)

*New PCR for “Printed products for waterless printing” was certified in Sep. 2012
*Cost of CFP logo on PR tool for Eco Product 2012 should be minimized
*Calculation results should be in +-5% range to utilize averaged figure
*Carbon calculation by 7-printer, then categorized into 3 groups based on the results
*Applying for CFP by group is effective to reduce application fee for SMEs


3.Utilization of PGG-CLOUD
PGG-CLOUD is developed for...

Assisting printers to work on carbon
calculation to get jobs
For carbon footprinting / carbon oﬀsetting

Following “print-buyers at the leading edge” to
defend jobs
For transformation of people’s subconscious



3.Utilization of PGG-CLOUD (cont’d)
Detailed 7-key feature are...
Calculating based on “clouding”
Calculating based on English/Japanese/Thai...etc.
Calculating by cumulative/allocation method
Calculating “full range of life cycle”
Calculating material input/output precisely
Calculating by massive database
Calculating results are summary/detailed (2-type)




Any kind of devices if it can access to internet

Computers Tablets Smart phones



Calculation: Select a job



RM: Case study “Introduction to Hangul”

Size: A5 (210mm*148.5mm)

Page: 4P+112P

Copy: 10,000 copies

Jacket: Coated paper, 157.0gsm,
2500+500sheets, 4-color+PP lamination

Cover: Fine paper, 157.0gsm,
1250+250sheets, 1-color

Text: Fine paper, 104.7gsm,
35000+1000sheets, 2-color on both sides

Binding: Perfect binding



Calculation: Substrate



RM: Emission Factors of papers
2.250

2.05 2.000
1.93
1.77 1.83 Fine paper
1.750
Coated paper
1.500 Non-bleached paper
Bleached paper
1.250
1.13 1.2 Carton box paper
1.19
1.000 Coated cardboard
0.750 Chipboard

0.500
0.250
Emission Factors (kg-CO2e/kg) 0

Reference: CFP communication program basic database ver.1.01


RM: “Piece of inventory data” comparison of R0% and R70%
(in order to make 1kg of “Fine Paper”)
Category Item Unit Fine P. (R0%) Fine P. (R70%) R70%/R0%

Energy electricity Wh 1.34E+02 1.69E+02 126.7%

Energy coal g 8.84E+01 2.47E+02 279.4%

Energy Black liquor BDg 1.31E+03 4.90E+02 37.5%

Energy Paper sludge BDg 1.81E+01 3.69E+01 37.5%

CO2
Emission (air) BDg 6.33E+02 9.81E+02 155.1%
(production)
CO2
Emission (air) BDg 3.39E+02 9.80E+01 28.9%
(forestation)
CO2
Emission (air) BDg 0.00E+00 1.78E+01 -
(recycling)
Reference: JLCA-LCA database 2012yr. 1st edition


Calculation: Material ﬂow



RM: Product area and non-product area
939mm
420mm
Paper area:
210mm
148.5mm 0.597204㎡
636mm

Product area:
594mm

0.498960㎡

Product area %:
83.5%



Calculation: Ink usage



RM: Calculation process of ink usage amount
Ink thickness

Maximum paper size of press Sheet run

Ink coverage %

0.001mm×1040mm×740mm×12%×36000sheet
×2-side÷1000 ÷1000=6.649kg
Convert to “kg”

Convert to “gram”

Print on both sides



Calculation: Ink transportation



RM: Check distance from start to goal by web



Calculation: Water (dampening solution)



RM: Scale factor of dampening solution



Calculation: Additives for dampening solution



RM: Breakout of dampening solution

14.89176kg×2.5 times=37.22940kg
→37.22940÷1.05=35.456571kg
→IPA=35.456571×3.5%=1.240980kg
→Additives=35.456571%×1.5=0.531848kg



Calculation: Printing plate



RM: Conversion of EF from “㎡” base to “kg” base
12.300 kg-CO2e/㎡ (0.400mm thickness)
→1.030m×0.785m=0.80855㎡＝80.855％
→0.240mm÷0.400mm=60.000％
→80.855%×60.000％=48.513%

→ 12.300 kg-CO2e/㎡×48.513%=5.967kg-CO2e/plate

→ 5.967kg-CO2e/plate×2-plate=11.934kg-CO2e/kg

Reference: CFP communication program basic database ver.1.01


Calculation: Design & Editing



RM: Actual monitoring of Mac quadra for 3-week
Electricity usage (kWh)
0.215

0.210

0.205

0.200

0.195

0.190

0.185

0.180

0.175 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10

*Line graph shown above is the monitoring data (once every 1-hour) for 3-week



Calculation: Computer to Plate (CtP)



RM: Actual monitoring of Prinergy server for 5-week
Electricity usage (kWh)
0.215

0.210

0.205

0.200

0.195

0.190

0.185

0.180

0.175 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10

*Line graph shown above is the monitoring data (once every 1-hour) for 5-week



Calculation: Press



RM: Break out of electricity usage by a press

R704 with perfecting unit

18%
Press
Pumps
Peripheraals
53%
29%



Calculation: Postpress



RM: Actual monitoring of air-conditioning
Time Winter (Feb.) Summer (Aug.)
8:00-9:00 9.85 kWh 15.81 kWh
9:00-10:00 9.65 kWh 17.45 kWh
10:00-11:00 11.15 kWh 17.35 kWh
11:00-12:00 8.65 kWh 15.19 kWh
12:00-13:00 7.35 kWh 16.39 kWh
13:00-14:00 7.65 kWh 16.44 kWh
14:00-15:00 5.55 kWh 15.43 kWh
15:00-16:00 6.25 kWh 14.47 kWh
16:00-17:00 6.05 kWh 18.64 kWh
AVG. 8.02 kWh 16.35 kWh
kWh % to rated output 32.1% 57.8%
20.00

18.00

16.00

14.00

12.00
Winter Summer
10.00

8.00

6.00
8:00- 9:00- 10:00- 11:00- 12:00- 13:00- 14:00- 15:00- 16:00-


Calculation: Delivery



RM: Weight calculation of wrapping paper

817.0mm
80mm 180mm 148.5mm 180mm 148.5mm 80mm
210mm

210mm

0.817m×0.210m＝0.17157㎡
→100gsm×0.17157㎡=17.2g/wrapping paper
→17.2g/wrapping paper×(10000÷20)=8.6kg



Calculation: Waste from household & factory



RM: Recalculation of material ﬂow



Calculation: Recycle from factory



RM: Recalculation of material ﬂow



Calculation: CO2e summary



For marketing tool (CFP label, Japan)

Reference: http://www.cfp-japan.jp


For marketing tool (CFP label, Korea)
How did they calculate CO2
for printing a package?

Reference: http://www.edp.or.kr/index_eng.asp


For sensitivity analysis (Best practice=Lightweight of paper)
kg-CO2e
6500
Recycle
Waste
-17.7% 5850
Delivery
5200 Water
Postpress
4550
Press
3900 CtP
3250 Design/Editing
Additives
2600
Plate
1950
Ink
Normal Practice 1300
Paper
650
Best practice 0


Sensitivity analysis (Environmental Load Point=ELP)
ELP
27,500,000
Landﬁll
10t-truck
24,750,000 4t-truck
-19.7% 2t-truck
22,000,000 Recycled Al
Recycled pulp
19,250,000
Electricity
16,500,000
Water
Ink (Plolyurethane)
13,750,000 Al
Paper
11,000,000
Environment impact categories of ELP:
8,250,000 1-Energy drain, 2-GWP, 3-Ozone depletion,
4-Acid rain, 5-Natural resource consumption,
5,500,000
Normal practice 6-Air pollution, 7-Water pollution,
2,750,000 8-Disposal problem, 9-Ecosystem eﬀect

Best practice 0

Reference: Nagata Lab., Waseda University Graduate School of Environment and Energy Engineering


Summary
Utilization of quantitative assessment for
“Eco-conscious Products”
a. Find “Hotspot(s)” to improve manufacturing process
and/or select eco-friendly material
b. Communicate with print-buyers (consumers) by
showing comprehensive internal comparison
c. Conduct many pilot projects to know efficiency of CFP
(environment impact assessment)

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!”


“고마웠습니다”
Thank you for your attention.
You can have a look at this presentation ﬁle:
http://www.slideshare.net/ShimizuHiro/edit_my_uploads
Corporate web site:
http://www.shzpp.co.jp


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