KroonpressSustainability Report 2013

KroonpressSustainability Report 2013Sustainability Report 2013

KroonpressSustainability Report 2013

KroonpressSustainability Report 2013

ContentsA 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 fl 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 en-vironmental 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 enforc-ing 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 environ-mentally responsible. In his words, sustainability is only the least negative on the scale of benefi t and harm – it is stagnation. If a producer achieves full sus-tainability, 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 benefi cial 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 specifi c parameters, a print job can be executed from cradle to gate with lower car-bon emissions than is stored in the fi nal 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 policyOur environmental policy is to increase stakeholder value by being more resource-effi cient, generating as little harmful waste as possible and endors-ing 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 im-pact 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 en-vironmental management certifi cate, ISO 9001 quality management certifi cate, Forest Stewardship Council (FSC) and, Programme for the Endorsement of For-est Certifi cation (PEFC) chain of custody certifi cates and the Nordic Ecolabel-ling license.

ISO 9001:2008 (certifi ed in 2001)This quality management systems standard aims to enhance customer satis-faction through the effective application of the quality management system.

ISO 14001:2004 (certifi ed in 2001) This environmental management systems standard specifi es requirements for an environmental management system to enable an organisation to develop and implement a policy and objectives which take into account legal require-ments and other requirements to which the organisation subscribes, and in-formation about signifi cant environmental aspects.

FSC (certifi ed in 2008), PEFC (certifi ed in 2009) FSC and PEFC certifi cation ensures that forestry operations meet a set of en-vironmental, social and economic criteria covering compliance with laws and international treaties, land-use and indigenous peoples’ rights, community re-lations, biodiversity conservation and maintenance of high conservation value forests, among other things.

This product is from sustainably managed forest and controlled sources.For more info: www.pefc.org

/19-31-02

Nordic Ecolabel (certifi ed in 2010)The Nordic Ecolabel is the Nordic countries’ offi cial 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 en-vironmental 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 infl u-ences clients’ decisions on choosing the smallest carbon footprint.

Achievements in sustainabilityGreenline PrintIn late 2012, we launched an online platform (www.greenlineprint.com) for car-bon 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 indi-cating their score on a scale of A to F.

A-class prints can be regarded as carbon positive because they emit less car-bon 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 eventu-ally result in the release of most of the contained carbon.

NORDIC ECOLABEL

541 787

Printing company

The calculator contains a database of over 120 papers and includes transporta-tion emissions right up to the client’s door. The service also notifi es 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 di-rectly from producers or, if absent, from high quality scientifi c literature. The calculation method follows the PAS 2050 specifi cation 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-specifi c 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.

www.greenlineprint.com

your own carbon footprint!Type it in and try calculating

Paper to kindergartensIn 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 kinder-gartens 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!

Rainwater recoveryWith the completion of our new warehouse, a 50 m3 tank for collecting rain-water was also installed. Rainwater is purifi ed 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 abun-dant 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.

Our paper delivery made front page news in the local Tartu Posti-mees daily newspaper.

S Ü N D M U S

Kl 18 esinevad Elleri muu-sikakooli saalis (Lossi 15) Tampere muusikaakadee-mia magistrant Hanna Lipiänen viiulil (klaveril Tii-

NELJAPÄEV, 6. DETSEMBER 2012NR 220 (3667)www.tartupostimees.ee

päeval +1

õhtul –1

lumeleb

kagutuul

3 m/s

� Trükikoja Kroonpress töö-tajad vedasid eile heatege-vusprojekti «Lasteaiad mu-rest priiks» raames mööda Tartu linna laiali 118 rulli pa-berit, et lasteaialastel oleks millegi peale joonistada.

ELINA RANDOJAelina.randoja@postimees.ee

Üsna järjekorra alguses oma kaksteist rulli paberit kätte saa-nud Sassi lasteaia õppealajuha-taja Regina Kullamaa rääkis, et nemad said paberi tänu Libli-kate rühma lapsevanemale, kes võimalusest kuulis ja teada an-dis.

Mida selle paberiga tehak-se, otsustab iga rühm ise. Võib-olla lõigatakse see väiksema-teks tükkideks, ehk saab seda

Kuhu hoiab soomepoisi südaAime Jõgi kohtus soo-mepoiss Evald Mäepa-luga ning küsis, kumb on tähtsam, kas Soome või Eesti Vabariigi sün-nipäev. / LK 8

T Ä N A

Heategevuskampaania kutsub lasteaedadele appi

Kroonpress viis lastele paberit

LED lighting in the new warehouse2012 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 detec-tors for darker periods. Compared to constantly operating 400W metal halide high-bay 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.

Energy auditKroonpress commissioned a full-scale energy audit in 2012, which analyzed the energy fl ows 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 specifi cally to production equip-ment, while the offi ce contributes only 0.3%.

We were notifi ed of the large excess heat dissipation from the gas dryers on the printing machines and work is under way to fi nd a solution to this in 2013.

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.

Targets for 2013100% renewable electricityWith 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 can-not 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 con-sumption. 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)!

CNG-powered trucks2013 will see at least one of our 9 trucks being retrofi tted with a compressed nat-ural 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

Energy company Eesti Energia has installed tens of wind tur-bines around the coastal ar-eas of Estonia and keeps close track of how much is produced and sold.

is a characteristic problem of diesel combustion. During the year, we will moni-tor 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.

LED-lighting in the old warehouseOur old warehouse was equipped with dying 400W high-bay lighting which will be replaced with the same high-effi ciency 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 fl ue gasesOur most ambitious plan in 2013 is to install a heat recovery system onto our KBA unit to capture the heat from the hot fl ue gases. Are hopes are high to replace up to 100% of our district heating with energy from fl ue gas heat recovery. If this project succeeds we will be cutting indirect greenhouse gas emissions by an extra 175 tonnes of CO2 per year.

CNG-trucks look and sound the same as their diesel coun-terparts but produce less CO2 and particulate matter.

Resource consumptionElectricity and natural gasElectricity 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 effi 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 con-sumed in 2012.

District heatingThe 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

Print output vs energy consumption

Natural gas MWh

Electricity MWh

Production, copies

Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec

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.

SubstratesThe 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.

District heating MWh

Average temperature

Heating vs outside temperature

Substrate consumption

Paper: 27 346 t

Aluminium: 96 tInk: 664 t

Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec

Energy auditThe results of the energy audit reassured that most of our energy bill is attrib-uted 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.

The graph shows our energy consumption profi le. Not unexpectedly, the op-eration of the large printing presses uses up a lot of electricity and especially natural gas for printing heatset publications.

Air emissionsOur harmful air emissions originate from natural gas incineration, ink evapo-ration and solvents used for cleaning and moisturizing. Why are they used?

Substrate consumption

ElectricityNatural gas

District heating

Other

Production processe

s

Administratio

n

Cooling

Domestic h

ot water

Space heating

Compressed air

Ventilatio

n

Internal transport

Lighting

Volatile organic compounds are used in inks to increase the speed of ink setting because their low boiling point enables quick and energy-effi 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 bet-ter 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.

The graph does not include CO2 emissions, which were 30 tonnes below per-mit levels, at 1846 tonnes per year. The following, along with CO2, are the only direct greenhouse gas emissions from our plant.

Air emissions

Permit

Actual

NO2 CO VOC

Tonnes per year

16

14

12

10

8

6

4

2

0

Water managementWe 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.

The majority of water was used for household purposes like bathrooms and washing, thus the waste parameters were similar to ordinary households. Bio-logical oxygen demand and total dissolved solids were well below permit lev-els, 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 fl 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 fi gures in this regard.

Wastewater quality (P, N)Limit

January

May

July

November

Wastewater quality (BOD, TDS)Limit

January

May

July

NovemberBOD7 mg/l

Phosphorus mg/l

Total dissolved solids mg/l

Nitrogen mg/l

Carbon footprintWith 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 oil-shale 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 Kroon-press-owned delivery trucks, which accounted for about 40-45% of all Kroon-press 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

Scope 1+2 carbon footprint 2012

District heating175 tCO2Electricity

8 601 tCO2

Natural gas 1 847 tCO2

Company cars48 tCO2Transport

589 tCO2

Scope 1

Scope 2

CO2 per employee

42 tonnesCO2 per revenue

310 tonnes/mln €CO2 per energy used

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 cur-rent and prospective customers to take a proactive and responsible attitude towards the climate impact that their publications infl ict.

We showed our goodwill towards the community of the city Tartu by organis-ing 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-effi cient high-bay LED lights were installed in our new warehouse complete with motion and light detection. During daytime, natural light fi lls 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 effi ciency 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 sheet-fed 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 effi ciency, less reliance on grid energy and a more socially responsible stance within our community. We hope to bring more good news again next time!

KroonpressSustainability Report 2013

Paper: Serixo 190, Amber Graphic 140Press: Heidelberg SM 102-9P5+LX

Design: Maarika MartinsPhotos: Maria Karolin

info: sander.jahilo@kroonpress.euID ae21100 g CO2