Kroonpress Sustainability Report 2013
Contents A Message from the CEO
4
Environmental policy
5
Achievements in sustainability
6
Greenline Print
6
Paper to kindergartens
8
Rainwater recovery
8
LED lighting in the new warehouse
9
Energy audit
9
Targets for 2013
10
100% renewable electricity
10
CNG-powered trucks
10
LED-lighting in the old warehouse
11
Heat recovery from ue gases
11
Resource consumption
12
Energy audit
14
Air emissions
14
Water management
16
Carbon footprint
17
Executive summary
18
A Message from the CEO Dear reader, 2012 was a busy year for the printing industry. Drupa demonstrated that environmental concerns run high for producers and service providers but green marketing didn’t exactly „steal the show“. It seemed as if marketeers were concerned with the issues, but didn’t really believe their efforts would stop the decline of print as a whole. Alas, in a demand-driven market, it’s the clients who decide the producers’ fate. Can we end prejudices towards print by enforcing environmental claims or will the market go its way? At the EcoPrint Show in Berlin last year, professor Michael Braungart said in his presentation that sustainability is a meagre attempt at becoming environmentally responsible. In his words, sustainability is only the least negative on the scale of benefit and harm – it is stagnation. If a producer achieves full sustainability, it will maintain a status quo of no harm to the environment but it will also do nothing to improve it. So, if there were products that were not just less bad but actually beneficial for the environment, wouldn’t that be perfect? We know some products that can do this in regard to climate change – our own prints! What we discovered while developing Greenline Print was that, given specific parameters, a print job can be executed from cradle to gate with lower carbon emissions than is stored in the final product. With FSC and PEFC forests expanding, all harvested biomass is replaced with new biomass and all wood products become carbon carriers. In effect, this makes certain prints carbon positive, not just carbon neutral! This sustainability report provides you with a status update on the current parameters of our operations, our achievements during the last year and sets new goals for 2013. Enjoy!
Environmental policy Our environmental policy is to increase stakeholder value by being more resource-efficient, generating as little harmful waste as possible and endorsing a life cycle perspective into printing in order to increase responsibility in other value chain participants. Our primary environmental responsibility is to monitor and minimize the impact of our own operations. We do this by following strict EU and national regulations on waste generation. Our secondary responsibility is our voluntary obligation to adapt to even stricter voluntary limitations and norms. We currently hold the ISO 14001 environmental management certificate, ISO 9001 quality management certificate, Forest Stewardship Council (FSC) and, Programme for the Endorsement of Forest Certification (PEFC) chain of custody certificates and the Nordic Ecolabelling license.
ISO 9001:2008 (certified in 2001) This quality management systems standard aims to enhance customer satisfaction through the effective application of the quality management system.
ISO 14001:2004 (certified in 2001) This environmental management systems standard specifies requirements for an environmental management system to enable an organisation to develop and implement a policy and objectives which take into account legal requirements and other requirements to which the organisation subscribes, and information about significant environmental aspects.
FSC (certified in 2008), PEFC (certified in 2009) FSC and PEFC certification ensures that forestry operations meet a set of environmental, social and economic criteria covering compliance with laws and international treaties, land-use and indigenous peoples’ rights, community relations, biodiversity conservation and maintenance of high conservation value forests, among other things.
/19-31-02 This product is from sustainably managed forest and controlled sources. For more info: www.pefc.org
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Nordic Ecolabel (certified in 2010)
IC E C OL A B
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541
787 Printing company
The Nordic Ecolabel is the Nordic countries’ official environmental ecolabel. It assesses the entire environmental impact of a printing company’s activity – everything from the choice of paper approved by the Nordic Ecolabel to good practices in making work environmentally friendly. Our next level of environmental concern was to create a new channel of environmental communication to give stakeholders accurate information about the carbon footprint of print. For this purpose, Greenline Print was developed. The service provides online carbon footprint calculatation and grading, along with issuing tagged labels. The calculator is based on extensive background research on the life cycle greenhouse gas emissions of our print products and includes emissions from paper, ink, printing plates, energy and transportation. This online tool gives our clients the opportunity to compare the emissions of their orders to the best case scenarios on a scale of A to F. Thus, the tool influences clients’ decisions on choosing the smallest carbon footprint.
Achievements in sustainability Greenline Print In late 2012, we launched an online platform (www.greenlineprint.com) for carbon footprint grading, assessment and labelling. The aim of the service is to calculate life cycle greenhouse gas emissions of any print order at Kroonpress and make the results easily understandable to publishers and readers by indicating their score on a scale of A to F. A-class prints can be regarded as carbon positive because they emit less carbon dioxide equivalent emissions over their cradle-to-gate lifecycle than they contain carbon. However, the end of life of print products is the big question mark – if consumers throw their prints away, paper degradation will eventually result in the release of most of the contained carbon.
The calculator contains a database of over 120 papers and includes transportation emissions right up to the client’s door. The service also notifies users if their footprint could be improved by changing print parameters. Behind the friendly and easy interface lies a lot of data that was collected directly from producers or, if absent, from high quality scientific literature. The calculation method follows the PAS 2050 specification for the assessment of the life cycle greenhouse gas emissions of goods and services, issued by the British Standards Institution. Through this service we aim to direct our clients to use papers that have smaller carbon footprints and to promote their environmentally conscious choices by placing the order-specific labels on their products. Each label comes with an online page with infographics to increase reader awareness of the sustainability and carbon footprint of each print product.
w w w.greenl inepr int.com Type it in and try calculating your own carbon footprint!
Paper to kindergartens In December 2012, Kroonpress participated in the „Lasteaiad murest vabaks“ („Let’s help kindergartens“) campaign hosted by donation-portal Spunk.ee by donating and transporting discarded reels of paper to all interested kindergartens within the Tartu region. In total, 26 kindergartens were donated 173 reels of paper with each reel containing approximately 40-50 metres of paper. The delivery day was met with smiling faces from all the kindergarten staff and children. The event even made the local news! NELJAPÄEV, 6. DETSEMBER 2012 NR 220 (3667) www.tartupostimees.ee päeval +1 õhtul –1 lumeleb kagutuul 3 m/s
Heategevuskampaania kutsub lasteaedadele appi
Kroonpress viis lastele paberit Kuhu hoiab soomepoisi süda Aime Jõgi kohtus soomepoiss Evald Mäepaluga ning küsis, kumb on tähtsam, kas Soome või Eesti Vabariigi sünnipäev. / LK 8
TÄ N A SÜNDMUS Kl 18 esinevad Elleri muusikakooli saalis (Lossi 15) Tampere muusikaakadeemia magistrant Hanna Lipiänen viiulil (klaveril Tii-
Trükikoja Kroonpress töötajad vedasid eile heategevusprojekti «Lasteaiad murest priiks» raames mööda Tartu linna laiali 118 rulli paberit, et lasteaialastel oleks millegi peale joonistada. ELINA RANDOJA
elina.randoja@postimees.ee
Üsna järjekorra alguses oma kaksteist rulli paberit kätte saanud Sassi lasteaia õppealajuhataja Regina Kullamaa rääkis, et nemad said paberi tänu Liblikate rühma lapsevanemale, kes võimalusest kuulis ja teada andis. Mida selle paberiga tehakse, otsustab iga rühm ise. Võibolla lõigatakse see väiksemateks tükkideks, ehk saab seda
Our paper delivery made front page news in the local Tartu Postimees daily newspaper.
Rainwater recovery With the completion of our new warehouse, a 50 m3 tank for collecting rainwater was also installed. Rainwater is purified and fed into the printing lines to decrease groundwater consumption from the grid. The tank can supply production with about a week’s requirement of water. Rainfall is fairly abundant in the Estonian climate but evaporation and long periods of below-zero temperatures will expectedly hamper its consumption. We hope to cover about 15% of our annual total water consumption with rainfall.
LED lighting in the new warehouse 2012 saw the completion of our new 1200 m2 paper warehouse which uses natural light during daytime and 16 high-bay LED lights with motion and brightness detectors for darker periods. Compared to constantly operating 400W metal halide highbay lighting, annual energy consumption should be over four times smaller with our LED lights. During daytime, natural light from windows on the walls and up on the roof provides enough light to not require additional lighting at all. Staged for this photo, the 16 Philips LED-lights only turn on when there is movement in the warehouse and ambient light levels are low.
Energy audit Kroonpress commissioned a full-scale energy audit in 2012, which analyzed the energy flows and pinpointed opportunities for improvement. The results of the audit provided a few surprises but was otherwise what we expected. 77% of our total energy consumption is attributed specifically to production equipment, while the office contributes only 0.3%. We were notified of the large excess heat dissipation from the gas dryers on the printing machines and work is under way to find a solution to this in 2013.
Targets for 2013 100% renewable electricity With 2013 we said goodbye to fossil-powered electricity. Our new energy contract with Eesti Energia grants us 100% renewable electricity at base consumption. This electricity will be produced from wind and hydroenergy. However, we cannot avoid peaking consumption above base levels, which means that additional electricity acquired from the market is produced from unknown resources. We don’t expect peak electricity to account for more than 10% of our annual consumption. Through the use of electricity from renewable sources we will save approximately 8600 tonnes of CO2 per year, equivalent to removing about 2500 cars from the streets (at 20 000 km/year and 170 gCO2/km)!
Energy company Eesti Energia has installed tens of wind turbines around the coastal areas of Estonia and keeps close track of how much is produced and sold.
CNG-powered trucks 2013 will see at least one of our 9 trucks being retroďŹ tted with a compressed natural gas kit. Modern CNG engines emit about 20% less carbon dioxide equivalent than modern diesel engines, not to mention the lack of particulate matter which
is a characteristic problem of diesel combustion. During the year, we will monitor the performance of the CNG-kit on the engine and hopefully we can make forward-looking decisions based on this assessment by the end of the year. CNG-trucks look and sound the same as their diesel counterparts but produce less CO2 and particulate matter.
LED-lighting in the old warehouse Our old warehouse was equipped with dying 400W high-bay lighting which will be replaced with the same high-efficiency LED high-bay lights as in the new warehouse. The LED-lighting in the old and new warehouse should total about 90 MWh in energy savings.
Heat recovery from flue gases Our most ambitious plan in 2013 is to install a heat recovery system onto our KBA unit to capture the heat from the hot flue gases. Are hopes are high to replace up to 100% of our district heating with energy from flue gas heat recovery. If this project succeeds we will be cutting indirect greenhouse gas emissions by an extra 175 tonnes of CO2 per year.
Resource consumption Electricity and natural gas Electricity consumption varies according to production intensity. Traditionally, spring and autumn are busiest months for printers. The graph tells us that print production uses least energy per unit during high production levels. The cold season adds the nuance of additional heating from natural gas blowers. August is the most efďŹ cient month for production because there is no district or gas heating and production is near its peak capacity. If production were as high during the vacation period, June and July would be comparable. In total, 7.8 GWh of electricity and 9.2 GWh of natural gas energy was consumed in 2012.
Print output vs energy consumption
Natural gas MWh Electricity MWh Production, copies
Jan
Feb
Mar
Apr
May
June
July
Aug
Sept
Oct
Nov
Dec
District heating The winter of 2012 was fairly cold with an average temperature in February as low as -10.6°C, which was over four degrees lower than the long-time average for Tartu. In total, 1150 MWh of district heat was distributed, of which 66.7% was produced
from biomass. The remaining fossil-fueled energy generated an annual 175 tonnes worth of carbon emissions. The graph below shows our heating consumption curve alongside average daily temperatures for 2012 in Tartu.
Heating vs outside temperature
District heating MWh Average temperature
Jan
Feb
Mar
Apr
May
June
July
Aug
Sept
Oct
Nov
Dec
Substrates The main substrates at our printing plant are paper and ink, with aluminium printing plates playing a vital part in prepress. 27 350 tonnes of paper was consumed in 2012. The amount of ink consumed was 664 tonnes and 96 tonnes of printing plates were passed on for recycling. 19% of all paper consumed internally ended up as waste – mostly as paper scraps and newspaper waste. This is a fairly large amount of paper but luckily it is very high-grade and will all be recycled. Ink: 664 t
Aluminium: 96 t
Paper: 27 346 t
Substrate consumption
Energy audit The results of the energy audit reassured that most of our energy bill is attributed to production processes and not auxiliary activities, but we learnt about our large stand-by electricity waste and also constant heat waste from the gas dryers on the three heatset presses. The audit pointed out the sources of largest potential energy savings, among which were compressors, warehouse lighting and heat recovery. The latter two are currently being solved.
Substrate consumption Electricity Natural gas District heating
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es on ati ess r c t pro n is mi on i d t A uc rod
ng oli o C D
tw ho c i est om
ir on ng ort da ati ati sp e l e i n s t h n tra res Ve ace al mp n Sp o r e C Int
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ng hti g i L
Ot
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The graph shows our energy consumption proďŹ le. Not unexpectedly, the operation of the large printing presses uses up a lot of electricity and especially natural gas for printing heatset publications.
Air emissions Our harmful air emissions originate from natural gas incineration, ink evaporation and solvents used for cleaning and moisturizing. Why are they used?
Volatile organic compounds are used in inks to increase the speed of ink setting because their low boiling point enables quick and energy-efďŹ cient evaporation, leaving behind a stain-free solid pigment. One of the VOCs called isopropanol or IPA decreases water surface tension which enables printing plates to be moisturised, resulting in an accurate image transmission. Our main culprit for VOC emissions is the sheet-fed printing press which lacks a gas dryer because it does not need heat. The ink used in this press is 100% VOC-free, unlike our other inks. But due to the lack of a gas dryer, the VOC emissions from IPA and washing agents are directed straight into the atmosphere without incineration. Most VOC emissions from our other heatset presses are incinerated and thus degraded into less harmful CO2, NO2 and CO. We hope that product development in the ink industry manages to achieve better performing eco-friendly inks so that we could embrace them in our other printing presses. We emitted less than our permit in three emission categories – NO2, CO and CO2 – but breached the limit for volatile organic compounds. This was due to an unexpected production increase in the sheet-fed printing unit.
Air emissions
Tonnes per year 16 14
Permit
12 10
Actual
8 6 4 2 0
NO2
CO
VOC
The graph does not include CO2 emissions, which were 30 tonnes below permit levels, at 1846 tonnes per year. The following, along with CO2, are the only direct greenhouse gas emissions from our plant.
Water management We consumed 7 380 m3 of water in 2012 of which about a third was used in production processes for moisturising rollers to enable transmission of ink onto printing plates and paper. This water evaporated into the atmosphere through the ventilation and did not contain contaminants.
Wastewater quality (P, N) Limit January May July November Phosphorus mg/l
Nitrogen mg/l
The majority of water was used for household purposes like bathrooms and washing, thus the waste parameters were similar to ordinary households. Biological oxygen demand and total dissolved solids were well below permit levels, as was nitrogen and phosphorus content. With the completion of our new warehouse in the second half of 2012, two tanks of 25 m3 were installed under its oor to store rainwater captured from the roof. The amount of rainwater collected was negligible in 2012 due to the late installation but 2013 will provide us with some interesting ďŹ gures in this regard.
Wastewater quality (BOD, TDS) Limit January May July November BOD7 mg/l
Total dissolved solids mg/l
Carbon footprint With revised indirect carbon emissions data, we found our scope 1 and 2 (direct emissions plus indirect emissions from energy consumption) carbon footprint had grown by 17% compared to our last report in 2011. This was due to the changed mix of resources in electricity production – in 2012, renewable energy subdsidies from biomass were unexpectedly placed under a cap which was lower than the planned output power for the year and thus the share of oilshale based energy increased. Our scope 1 emissions (direct emissions from our plant) were 2 484 tonnes of CO2, scope 2 emissions (indirect emissions from energy bought from the grid) accounted for 8 776 tonnes of CO2 . Transport emissions included emissions from company vehicles and Kroonpress-owned delivery trucks, which accounted for about 40-45% of all Kroonpress transports; these were mainly domestic deliveries. All export-bound shipping was outsourced and is not included in this carbon footprint analysis.
Scope 1+2 carbon intensity 2012 Transport 589 tCO2
Company cars 48 tCO2
District heating 175 tCO2
Electricity 8 601 tCO2
Natural gas 1 847 tCO2
Scope 1 Scope 2
Scope 1+2 carbon footprint 2012 CO2 per employee
CO2 per revenue
CO2 per energy used
42 tonnes
310 tonnes/mln â‚Ź
153 tonnes/GJ
Executive summary 2012 saw the development of Greenline Print, a service for calculating, grading and labelling life cycle carbon footprints of print products, guiding our current and prospective customers to take a proactive and responsible attitude towards the climate impact that their publications inflict. We showed our goodwill towards the community of the city Tartu by organising a giveaway of over 170 reels of leftover paper to 26 kindergartens in Tartu. A 50 m3 storage for collecting rainwater and system to feed this water straight into production was created in our new warehouse, decreasing our need for groundwater from the grid. 16 super-efficient high-bay LED lights were installed in our new warehouse complete with motion and light detection. During daytime, natural light fills the space with no need for additional lighting. An energy audit mapped our energy consumption hotspots and pointed to possibilities of decreasing energy losses by installing frequency control, changing lighting and recovering excess heat. The lowest-hanging fruit were then chosen for further analysis and we should be seeing changes in energy efficiency within 2013-2014. Emissions from water and air proved to be under control, except for excessive VOC emissions, which were larger due to increased production in the sheetfed unit. We consumed 27 346 tonnes of paper, 664 tonnes of ink and 96 tonnes of printing plates, emitted 2484 tonnes in direct CO2 and 8776 tonnes in indirect CO2 emissions. All in all, we are striving for more efficiency, less reliance on grid energy and a more socially responsible stance within our community. We hope to bring more good news again next time!
Kroonpress Sustainability Report 2013 Paper: Serixo 190, Amber Graphic 140 Press: Heidelberg SM 102-9P5+LX Design: Maarika Martins Photos: Maria Karolin 100 g CO2
ID ae21
info: sander.jahilo@kroonpress.eu