It’s been clear for many years now that processless printing plates are the way forward to improve sustainability in the printing business. They are increasingly the preferred option for printing companies keen to cut their carbon footprints, as well as saving time and money. Kodak recently presented some compelling data to encourage more European customers to switch to process free plates, specifically to the Kodak Sonora Xtra plate. This plate is made in Germany at the company’s Osterode factory. Printing plates have been made here since 1962 for customers throughout the European continent.

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This being a drupa year we’re expecting all sorts of new technologies to be presented in Düsseldorf in May. And not to be outdone, Fespa in Amsterdam is the site of a bevy of new technologies this month. Ricoh will introduce a new flatbed roll-to-roll printer and there will be many more new products to explore. There is certainly no lack of innovation, but we aren’t seeing enough being done when it comes to sustainability developments.

The problem isn’t so much with commercial print waste, since most of this is still paper based. Paper recycling is well-established in developed economies and although the paper industry is slacking when it comes to digital print deinking and recycling investments, the model is at least there. At some point the necessary upgrades will be made.

Press technologies are also readily recycled and here too a model is in place. Ricoh, Canon, HP and Xerox have long since reused skins and other components from devices they have reclaimed for reuse. And printing presses have very long lifespans, assuming parts and consumables are still available. But more seriously we have new inks and substrates that cannot always be easily parted. This compromises paper recycling and will undermine the considerable advances made in the industry’s environmental sustainability in the last few years. That said, in the commercial print sector we have an established foundation and supply chains for improved sustainability. The same cannot truly be said for the packaging sector where innovation, particularly in materials science may be spurring more problems than it solves.

In the last few years we have seen some gorgeous innovations in shapes and sizes of packaging, thanks to innovation in substrates, inks and packaging systems. There has been a trend towards smaller packages and multipacks, packages within packages which suits the market but drives excess packaging consumption. This inevitably generates waste, much of which gets burned rather than being put into established recycling streams.

According to data from the European Union (EU), each European generated an average of over 188kg of packaging waste, ranging from 73.8kg per person in Croatia to more than 246kg per person in Ireland. The EU’s goal is to recycle 70% of packaging waste by 2030, from all sources but perhaps we shouldn’t be generating so much of it in the first place. That is much easier said than done, but as with judicious use of print which is now a commonplace, we can all think more carefully about the packaging waste we generate. 

Laurel Brunner

This article was produced by the Verdigris Project, an industry initiative intended to raise awareness of print’s positive environmental impact. This weekly commentary helps printing companies keep up to date with environmental standards, and how environmentally friendly business management can help improve their bottom lines. Verdigris is supported by the following companies: Agfa Graphics, EFI, Fespa, Fujifilm, HP, Kodak, Miraclon, Ricoh, Unity Publishing and Xeikon.

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Through this initiative, Clean Agency also developed an LCA tool that EFI customers can use to analyse their CO2 equivalent (CO2e) emissions as part of overall packaging extended producer responsibility (EPR).

According to the LCA, printing corrugated materials on an EFI Nozomi digital press reduces global warming potential (GWP) by approximately 50% when compared to analogue printing technologies.

Seri McClendon, CEO of Clean Agency, said, ‘No printing plates, less energy, less waste, and just-in-time (JIT) manufacturing all contribute to CO2e reductions for corrugated printing on EFI’s Nozomi digital press.

‘Packaging is a major contributor to Scope 3 emissions, so we not only partnered with EFI to conduct the LCA but also to build a calculator that enables users to quantify related kilograms of CO2e for specific packaging printing volumes and applications.’

Evandro Matteucci, EFI’s vice president and general manager of building materials and packaging, stated, ‘The insights substantiate digital print’s positive impact on sustainability as well as our overall commitment to our own and our customers’ sustainability goals.

‘The LCA tool is a key value proposition for all users, as the ability to demonstrate clear footprint reductions not only aligns with ethical values but also enhances brand reputation and competitiveness in the market.’

In 2023, UK converter Caps Cases has claimed to have saved 300,000kg of CO2e when compared to analogue production methods, following its investment in the world’s first EFI Nozomi 14000 LED single-pass UV LED inkjet press.

Trevor Bissett, CEO of Caps Cases, commented, ‘According to our calculations, our largest customer avoided 60,000kg of CO2e by switching to Nozomi digitally printed packaging in 2023. To have the ability to communicate this calculation and its impact provides a strong testimonial for our digital print solutions and indicates our commitment to being a sustainable manufacturer.’

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The new grades are Advantage, Essential and ProFilm. Advantage is suitable for litho-based lamination in applications such as magazines, brochures and book covers. It is available in gloss and matt finishes across a wide range of sizes.

Essential is a film range with  options suitable for both litho and digital print. Its finishes include matt, gloss, silk and ‘soft allure’ for the enhancement of magazines, brochures and packaging, with an antibacterial version for added protection.

The ProFilm films are designed to help enhance and embellish business cards, luxury packaging, menus and similar items. ProFilm is also available in a range of visually attractive and tactile textured finishes such as leather, sand and linen.

‘This announcement marks an exciting move for Premier,’ commented Phil Marfella-Smith, digital and specialist products manager at Premier. ‘By launching these new grades of lamination film, we offer an improved choice to our customers whilst maintaining range integrity and continuity.’

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The HP Wrap Camp will take place at the new PressOn facility in Whitstable on 13 March 2024, while the HP Sustainability Bootcamp will run on 14 March 2024 at the nearby PressOn Chatham site.

The HP Wrap Camp will offer attendees insight into the vibrant market of vehicle wrapping. The event will aim to help visitors learn about the entire wrapping process, from printing via laminating and cutting to applying graphics onto vehicles.

Paige Walton, founder and CEO of The Vehicle Wrapping Academy, will be in attendance and carrying out live demonstrations of wrapping, offering further guidance and advice to visitors.

The second event, in Chatham, will focus on the value of sustainability for the modern wide-format print and signage business. Hosted by the Make it Happen signage consultancy, on behalf of HP and PressOn, the Sustainability Bootcamp is a workshop that hopes to bring together corporations, companies and individuals to learn, discuss and share knowledge and ideas. In addition to highlighting how HP Latex print technology could support visitors with their long-term environmental goals.

Sarah Magee, the marketing manager of the Make it Happen signage consultancy, and Steve Lister, formerly head of sustainability at HH Global and now founder of Rethink Retail, will both speak at the event about the importance of the environment and offer advice to attendees about how their businesses can become more sustainable.

Jane Rixon, business development manager of large format production at HP spoke on the importance of teaming up with PressOn and other companies. She said: ‘We are delighted to be teaming up with our long-term partner PressOn to host these two special customer events.

‘While the events are very different in subject matter, both are equally important in terms of the value they offer to visitors.’

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A solar array with 1276 photovoltaic panels was connected to the electricity grid in February 2024. It was installed on the roof of SwissQprint’s main production hall and according to the company, will produce approximately 613,000kWh of electricity a year. This corresponds to more than half of the electricity demand at the Schützenwiese business park.

The installation will also power eight newly constructed charging stations for electric vehicles. Reto Eicher, co-owner of SwissQprint and project coordinator explained the benefits of the installation commenting, ‘The solar project brings us a big step forward in terms of sustainability and self-sufficiency.’

When the business park was built in 2013/14, the construction clients including SwissQprint emphasised the importance of sustainability. Tasks such as building services were dependent on fossil fuels, interiors were heated and cooled by groundwater, plus there was need for electric pumps to drive the heat exchange system. This will now be powered by the solar panels.

The Schützenwiese business park is described as exceeding the standard for industrial buildings. An objective throughout the business park was optimised temperature management. The insulation R-value of the building envelope and windows, as well as automatic sun blinds is key to achieving this.

Other factors aimed at achieving more sustainability within the entire building complex is the use of energy-saving LED lighting. Furthermore, both SwissQprint production halls have saw-tooth roofs that admit ample natural light into the building interior. As a result, artificial lighting becomes more unnecessary and further reduces electricity consumption.

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Young People In Print (YPIP) aims to ‘cultivate a passion’ for entering the industry by connecting schools and universities with local print facilities and organising ‘engaging events’ that promote print as an attractive career.

One of the group, Elizabeth Bowerman, head of UK sales at Stephen Austin & Sons, commented, ‘We are reaching out to schools and universities to enable students to see for themselves how amazing the print and packaging industries really are.’

Joining Ms Bowerman are Paul Stead of ASL group, Joanna Stephenson of PHD Marketing, Kelvin Bell of VPress, Lucy Swanston of the SMP and Nutshell Creative and Delroy Simmons of Dayfold.

According to 2023 BPIF data, the UK print sector has an annual turnover of £13.7 billion and employs around 98,000 people in 7,200 companies, meaning it remains an important economic contributor in all UK regions. It is also an advanced manufacturing sector, utilising innovation, and production technologies, connecting organisations around the world. Despite this, attracting young people to work in the industry continues to be a challenge.

Ms Bowerman pointed to an aging skilled workforce and the lack of formal print-based education available today as being major concerns for the print industry in the UK. She said, ‘The number of tradespeople working in print is plummeting – by 73% between 2006 and 2021 according to the latest data.

‘Workers are approaching retirement and there is a risk their skills will be lost, which could have serious consequences for our industry if not mitigated.

‘Sadly, our industry has an old-fashioned image, and there is very limited print or packaging education available today, apart from print apprenticeships, but even then, not all printers are using their levy to fund employees.’

Other factors cited by Ms Bowerman as discouraging young people from joining the sector are the often negative environmental perceptions about the print industry and competition from better-publicised industries like aviation, engineering, automotive and biotech.

To combat the lack of youth joining the industry and to try and change its perception, Ms Bowerman concluded, ‘YPIP has been established to promote the industry as a far more dynamic, high-tech, innovative, connected, and exciting place to work, with clear career progression routes and opportunities.’

The group said it will hold its first event connecting students and print facilities in March 2024.

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Made in Europe to the same manufacturing process and standards as before and available from stock, the re-launched Rives range includes the familiar textures of Laid, Design, Linear, Shetland and Tradition alongside Rives Sensation and new addition, Rives Digital, suitable for both dry toner and HP Indigo applications, which is available in convenient split-pack quantities.

The felt-marked textures with geometric and fabric-inspired patterns are made using marking cylinders to give a subtle yet highly visible texture. The papers are FSC–certified and carbon balanced as standard through Antalis’ partnership with World Land Trust. Antalis suggests that Rives is ‘the ideal choice for corporate communications and creative applications such as greeting cards, brochures, publishing and luxury print’.

Sales manager for creative papers at Antalis, Vicky Weatherington, commented, ‘Rives has long been a favourite of brands and designers, so we are delighted to be able to bring this beautiful, tactile range back to market. Rives afficionados can rest assured that the range continues to be made to the same high standards as when it was first produced in the French city of the same name.’

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Now in the top 1% of printers in the UK to have achieved this certification, Blackmore has looked for further improvement, making more investments to reduce emissions. These investments include new solar panels, energy-efficient print presses, a new air compressor, as well as changing the energy supply so that all the electricity used during production is from 100% renewable sources.

World Land Trust has currently offset over 380,000 tonnes of CO2 as result of Carbon Co and its carbon balanced print and paper programme.

Blackmore is looking continue this progress by aiming to halve its Scope 1 and Scope 2 carbon emissions by 2030.

Looking towards this goal managing director of Blackmore Andrew Robbins explained, ‘With the combination of our investments in the Carbon Balanced Printer certification, new solar panels, state-of-the-art print presses, renewable energy supply and partnership with greener suppliers, we are well on our way to achieving our goal of net-zero this decade.’

Speaking on the benefits of the certification achievement Mr Robbins added, ‘We previously offered a carbon balanced paper service, although we wanted to go the extra mile, so we made the necessary measures to become a Carbon Balanced Printer.

‘This means that not only are we committing to offsetting any carbon emissions through the World Land Trust, our customers can also benefit by including the World Land Trust Carbon Balanced Print logo on their relevant print projects created by Blackmore.’

Carbon Co partnership director Paul Opie expressed his thoughts on Blackmore’s achievement stating, ‘Carbon balanced printers, such as Blackmore, are leaders in sustainability who recognise the critical and continuing need to reduce avoidable emissions wherever possible and take direct action.

‘We are delighted to welcome Blackmore as a certified Carbon Balanced Printer through our programme in partnership with World Land Trust.’

The achievement adds to Blackmore’s previous environmental credentials as it also holds the ISO:14001 environmental certificate.

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3 Sixty serves the retail, visual merchandising, exhibition, event and commercial interiors sectors. Managing director Richard Inkin said, ‘The P5 350 HS gives us huge versatility due to the hybrid capabilities as well as the high speed and quality levels it can achieve. Its handling of some of the more unique materials we use was also a big tick in the box.

‘The incredible performance levels mean we can now work more efficiently throughout the business, as print is only one element of many in getting a job out of the door. Having more time now to cut, collate and pack the jobs has given us more flexibility in the way we work. The P5 speed levels mean that we will not need to run anywhere near the high speeds it can achieve and still increase our capacity by more than 30% without the extra costs that we would think we would have incurred. Print is about manufacturing a high quality product from start to finish, not just how quickly you can print it.

‘The flexibility of the machine allows us now to go after more business across all sectors we work in – retail, events and the exhibitions sectors to name a few. We know that our clients will see the benefits of our investments which have only been possible with their support of both our customers and our suppliers. Durst was brilliant, along with Compass Business Finance, in putting the deal in place and therefore helping us to focus and drive forward. 2024 has exciting opportunities for everyone but also if we are all honest, a degree of uncertainty, so investment in the right type of equipment is key. We are sure we have made the right decision.’

Mr Inkin also explained that the business aims to make ‘significant’ investments ever two or three years, in order to have up-to-date technology and to maximise environmental performance with regards to inks, material developments and reducing power consumption.

‘Having looked at the offerings available through partners we already have and other manufacturers, we decided to go with Durst because of the technology in the machine and we were confident in continuing a strong and long-term relationship,’ he concluded.

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