Sustainable Platemaking
2011 Update
Ray Bodwell
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Agenda
 Recap - Sustainability Pressures Across Value Chain
 DuPont & Sustainability
 Cyrel® and Sustainability
 TR3 – Return, Reuse, Recycle
Drivers Across the Value Chain
The Original Push: Wal-Mart 7R’s & Scorecard
7 “R’s” 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).
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)
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Drivers Across the Value Chain
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5
Drivers Across the Value Chain
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Global Drivers
It’s no longer a
question of whether
or not EPR will
come to America;
it’s only a question
of when and on
whose terms.”
Julian Carroll,
EUROPEN
EUROPEN – The European Organization
for Packaging and the Environment
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
Drivers Across the Value Chain
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Sustainable Packaging Coalition
Material
Use
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
Clean
Production
Technologies
Water
Use
Energy
Use
Material
Health
Community
Impact
Cost &
Performance
Worker
Impact
Drivers Across the Value Chain
“Greening the Supply Chain”
Logistics
Sourcing

Carbon Footprint Strategy

Waste Disposal

Packaging / Product Design

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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.
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DuPont & Sustainability
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DuPont “Scorecard” & Systems Thinking - 2006
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.
Up Stream
Raw Material
Acquisition
Raw
Materials
Energy
Down
Stream
Recycle
Transportation
Coproducts
Manufacturing
Air Emissions
Transportation
Waterborne
Wastes
Use/Reuse/
Maintenance
Solid
Wastes
Waste
Management
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We Do Take Actually It Seriously
DuPont Life Cycle Analysis
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DuPont – LCA’s
First objective :
Second objective :
Benchmark the environmental
performance of Flexography
versus Rotogravure printing for
the flexible packaging and tag &
label markets.
Compare the environmental
performance of solvent-based and
thermal (Cyrel® FAST) flexographic
plate imaging technology.
Functional unit = area of printed
substrate (m2)
Functional unit = area of imaged plate
(m2)
Note : Liquid and water washable plates
were not included in this study.
DuPont Life Cycle Analysis
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Definition: Life Cycle Assessment (LCA)
 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
DuPont Life Cycle Analysis
Results…
1st step : Original LCA  data from 2006-2007
 publication in September 2008
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.
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DuPont Life Cycle Analysis
15
0.40
9.0
0.35
8.0
7.0
0.30
6.0
0.25
5.0
0.20
4.0
0.15
3.0
0.10
2.0
0.05
1.0
0.00
0.0
Average Aligned Average Aligned
Flexo
Gravure
Average Aligned Average Aligned
Flexo
Gravure
Non-Renewable Energy Use (MJ per m2 of product)
Greenhouse Gas Emissions (kg CO 2 e per m2 of product)
Original LCA
Flexography vs. Rotogravure
Average 50% Savings
with Flexographic
Printing
Flexography :
• Higher viscosity inks reduces
solvent use
• Reduced energy & emissions
for drying
• Reduced substrate waste
Heat Credit & Recycling
Plate or Cylinder
Cardboard Cores
Electricity
Dryer & Oxidizer Fuel
Combusted VOCs
Aligned Plastic Substrate Model
Ink & Solvent Production
Substrate Film
DuPont Life Cycle Analysis
Estimated Savings: Flexography vs. Gravure
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
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DuPont Life Cycle Analysis
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Plate Processing Workflows
Solvent Process
Film/Analog
Laser/Digital
Total Production Time: 2.5 – 4.0 hours
Thermal Process
Film/Analog
Total Production Time: 30 – 45 mins.
Laser/Digital
DuPont Life Cycle Analysis
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Average Digital Flexographic Plate Imaging Impact
Cyrel® FAST has a
63% lower non-renewable
energy consumption
Cyrel® FAST has a
52% lower greenhouse
gas emissions.
250
18
16
15.2
200
10
7.3
8
100
81
6
4
50
Solvent & Recycle
2
(kg eq. CO2 / m )
150
Greenhouse Gas Emissions
14
12
(MJ / m2)
Non-Renewable Energy Consumption
216
Light Finisher
Dryer
Processor & Developer
Main Exposure
Ablate Image
Back Exposure
2
0
0
0.067 Updated
Digital Solvent
Average
0.067 Digital
Thermal
0.067 Updated
Digital Solvent
Average
0.067 Digital
Thermal
* With DR 44 fiberweb
DuPont Life Cycle Analysis
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Updated LCA Results – Solvent vs.. Thermal
Digital thermal = 63% lower energy & 53% lower ghg vs. solvent
250
18
150
10
8
100
6
4
50
2
0
0
0.067
Original
Digital
Solvent
Average
0.067
Updated
Digital
Solvent
Average
0.067
Digital
Thermal
0.067
Original
Digital
Solvent
Average
0.067
Updated
Digital
Solvent
Average
0.067 Digital
Thermal
Figure 1: Average Digital Flexographic Plate Imaging Impact
Solvent & Recycle
2
12
(kg eq. CO2 / m )
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Greenhouse Gas Emissions
200
(MJ / m2)
Non-Renewable Energy Consumption
16
Light Finisher
Dryer
Processor & Fiberweb
Main Exposure
Ablate Image
Back Exposure
DuPont Life Cycle Analysis
Estimated Savings: Solvent-free System
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
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DuPont Life Cycle Analysis
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Down-gauging:
2.0
25
1.8
1.6
20
1.4
15
1.2
1.0
0.8
10
0.6
5
0.4
0.2
0
Greenhouse Gas Emissions kg
eq.CO2 / ft2
Non renewable Energy Consumption
(MJ/ft2)
Source Reductions through Down-gauging
0.0
0.067
Analog
Solvent
0.112
Analog
Solvent
0.25
Analog
Solvent
0.067
Analog
Solvent
0.112
Analog
Solvent
0.25
Analog
Solvent
Based on DuPont Life Cycle Assessment Study
Solvent & Recycle
Processor & Fiberweb
Light Finisher
Main Exposure
Dryer
 Reduces overall
footprint
 Reduces drying time
 Reduces solvent use &
recycling
 Reduces energy
consumption &
greenhouse gases
Back Exposure
Other benefits:
 Less board strength
losses
 Improved graphics
 Supply chain reductions
DuPont Life Cycle Analysis
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Does This Really Matter?
• Yes
Gravure vs. Flexo is meaningful and should matter to Wal-Mart
• Yes
Thermal vs. solvent also impactful over time, volume and
multiple SKU’s
• Yes
Down gauging plates has a measureable energy and CO2 savings
that can also be impactful over time, volume and multiple SKU’s
What about liquid and water wash plates?
• We don’t make them so we didn’t measure them
• All questions about energy and carbon footprint apply
• Follow ISO 14040 Guidelines
• Key questions around water consumption and waste water generation
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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!!
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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 don’t have access to
clean water and 2.5 billion lack proper sewage and sanitation. According to estimates, demand for
freshwater will exceed the world’s 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 waterintensive 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?
DuPont Life Cycle Analysis
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Water Considerations
Aging infrastructure, climate change, strained city budgets
RI Considers Raising Water
Bills to Protect Supply
By THE ASSOCIATED PRESS
Published: October 5, 2009
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.
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.
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
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But it’s The
not just
plate processing
Waste:
Goalabout
is Zero
Goal: Expand and develop suitable recovery, reuse or recycling options for all Plant waste &
everything that we ship to Customers
Recover,
Reuse, Recycle
2
0
0
9
Products & Packaging
Waste
Manufacturing
Customer
Reuse
EnergyfromWaste
Incineration
Post
Manufacturing
Reuse
Applications
 PACKAGING Waste– e.g. polystyrene, gaylords,
foam…
 PLATE Waste – Plates, Trim,
 CONSUMABLES – butt rolls, base & cover sheets,
Binders, Polymers
New Commercial
Applications
T
O
D
A
Y
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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
DuPont TR3
DuPont TR3 – Return, Reuse, Recycle
Disposal
or
Recycling
Use,
Reuse &
Maintain
Acquire
Raw
Materials
Cradle-toGate
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Cradle-toGrave
Design &
Produce
Package
&
Distribute
 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)
DuPont TR3
Recycling Challenges – Who to partner with?
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
We’ve 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
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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
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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 where’s the catch?
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DuPont TR3
Polymer Separation Requirements
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
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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
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DuPont TR3
Program Status
 In external evaluation > 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
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Additional Resources
raymond.w.bodwell@usa.dupont.com
Resources – Sustainability Best Practices
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raymond.w.bodwell@usa.dupont.com
Resources – DuPont LCA Reports
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raymond.w.bodwell@usa.dupont.com
Resources
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Thank you!
raymond.w.bodwell@usa.dupont.com
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Advancing Flexography