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Print Process Champions members and partners are working on several cross-industry projects. If you would like more information then please
contact us.

>Optimized Paper Handling & Logistics — Best Practices
> CHAMPION PrintMark Quality Benchmarking
> Lean & Green Printing Plants
> Ecolabel for printed paper
> e2-Key Performance Indicators

Optimized Paper Handling & Logistics — Best Practices

A unique cross-industry collaborative project brings together the entire paper supply chain — from the mill, through transport, storage, handling and press preparation — to establish a common best practice tool and global reference for suppliers, transporters and printers to improve their efficiency. Substrates are the highest single cost for all printing applications and any reduction in their waste and damage improves both economic and environmental impact to give combined Lean and Green benefits. This initiative will collect, structure, share and promote generic best practices for paper handling and logistics for publishing and packaging applications for most print processes (offset, flexo, gravure, digital) using rolls and sheets of paper and board that share many characteristics. The guide will include modules on:

1. Paper, Cores, Wrapping & Pallets
2. Damage inspection & diagnosis
3. Warehouse/Paper store
4. Handling equipment
5. Best practice roll & pallet handling
6. Transportation: Rail, Road, Sea, Containers
7. Printer: Paper on to Press

The project was initiated by the Print Process Champion Group and WAN-IFRA with the European Rotogravure Association, IDEAlliance and NOPA, along with participating companies across the supply chain. The result will be a free 132-page E-Book financed by participating organisations and companies. Digital print-on-demand, or classic printed versions are also planned where users will pay only the production and delivery costs. For more information The first edition of the guide will be launched at WAN-IFRA Expo in October 2015.

Lean & Green Sustainable Printing Plants

This new best practice guide is being jointly published by Print Process Champions and IDEP France to provide an overview and international examples of sustainable printing plants. The printer’s building and its associated operating costs are usually (after its payroll) the company’s second highest expense and a major factor in determining its environmental impact. The energy consumed in buildings is about 25-40% of final energy consumption, plus the related carbon footprint. Some printers have re-invented their working environment to improve their overall economic and environmental efficiency — a ‘lean and green’ strategy. It must be recognised that the printing industry is part of an eco system in which climate change, pollution, extreme weather events and resource availability are issues that affect every part of the globe.

Nine international case studies were conducted for this new guide Lean & Green Sustainable Printing Plants to share the experience of companies that have made the transition to more sustainable printing plants, either in new or renovated buildings. They range from small to mid-size commercial and packaging printers in different meteorological zones in North America, Japan and Europe Case studies Sustainable Printing Plants. All of these companies are successful in their respective markets, and continuously optimise their working and environment practices. They commonly identified their eco-building projects as a major step in completing their business and environmental strategy, improving working conditions, and reinforcing competitive differentiation. Their additional costs for more sustainable construction are offset by reduced operating costs and improved lifetime performance.

If you would like your printing plant included in this series please contact us.

CHAMPION PrintMark Quality Benchmarking

A cost effective and simple continuous improvement tool to monitor and improve print production colour quality. Confidential benchmarking (not press fingerprinting) allows performance comparison and monitoring over time of one or more presses. It provides an independent assessment of copy-to-copy variation and colour change through the run, which if repeated on a regular basis can quantify the impact of process improvement actions. PrintMark is run by the Welsh Centre for Printing and Coating (WCPC) on behalf of the Print Process Champions. The WCPC, an internationally renowned open access centre for printing research and development, is part of Swansea University...
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Ecolabel for printed paper — a newspaper case study

The EU Ecolabel is a voluntary elitist label that can only be used by 20% of volume in a given market. Its aim is to help purchasers identify products with a reduced environmental life cycle impact. The Ecolabel logo on Printed Paper products conveys it is “recyclable; uses paper with low environmental impact; and emissions of chemicals to air and water of paper production and printing process have been limited.” The EU claims that the label adds value to businesses. However, for printed paper products these benefits are less obvious. The Ecolabel is only one element in environmental printing performance.

The newspaper has been selected as a case study example because it is a ‘simple’ print product. The project’s objective is to better understand the label, implications of procedures to become certified, and value to different stakeholders — ink and chemical suppliers , paper manufacturers, printers, publishers and national bodies — who can then each make an informed decision on their interest to use the label or not.

This project is organised by Print Process Champions with the Danish Printers Federation, WAN-IFRA, UNIC, Ecograf, Boettcher, Sun Chemical and UPM.

e2-Key Performance Indicators
Lean & Green Workshops in India

Economic & Environmental Key Performance Indicators (e2-KPIs) is an on-going Print Process Champions (PPC) project to identify, improve and monitor these related efficiency parameters. The goal is to select a limited number of indicators that have the maximum economic and environmental impact on a print site - this overcomes the risk of having too many non-comparable benchmarking indicators. The concept has been developed in Europe by PPC in partnership with ClimateCalc, Vision in Print and ECOGRAF. It is currently being tested in India and will be made available for use anywhere in the world.

Since mid 2013, Benoit Moreau of ECOGRAF, a PPC Associate, has been accompanying Indian newspaper printers within the Grow Green project of WAN-IFRA South Asia. Workshops have already been made with 4 newspaper publishers at 6 production sites using coldest and heatset production. Each 4-day workshop included training, a site visit and identifying an improvement programme that included the presentation and use of e2-KPIs.

In the context of its Lean & Green approach, - identified 12 indicators that measure the evolution of consumption of a print site either internal (from one year to another) or externally between different production sites. Benchmarking indicators like the measurement of energy efficiency, paper consumption, or plate chemistry allow their optimization. In most cases these indicators can be established from data collected for calculating the carbon footprint with the aid of the ClimateCalc software, and no additional research is necessary. The defined indicators were tested in real conditions in Indian companies to confirm their pertinence. One of the participants requested the addition of an indicator to monitor lubrication oil consumption - because the same presses in some plants present a huge mineral oil consumption, while other are very low.

At the close of each workshop there is an action meeting where these e2-KPIs were an indispensable aid to define improvement actions for environmental and economic performance.

This action is a first step. The next step is to collect, with the aid of different partners of PPC, input from all over the world to build an international data base - with assured confidentiality - to allow printers to compare themselves in a way that allows them to identify their strengths and weaknesses from which to introduce appropriate improvement actions. For more information
Chart — Three example of e2-KPI indicators — energy, CO2-e emissions and paper waste.

EXCEL CHART
These examples show the interest to present e2KPIs on the same chart using an average equal to 100. If the answers are not obvious, then it allows the right questions to be formulated, for example, the first step could be to understand why "site D" is always higher than the average, and why "site A" energy consumption is very low compared to the average but equal to the average for CO2 emissions.



PHOTO
Times of India Green Circle participants.



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