Resource Categories: Sustainability

Case Study: Jet Press 750S HSM & 720S

Ebro Color

Case Study

Packaging printer Ebro Color benefits from multiple Jet Press installations, thanks to quality and food-safe ink.

Ebro Color

Albstadt, Germany

Jet Press 750S HSM & 720S

Highlights

  • Ebro Color is a cardboard packaging print specialist based in Albstadt, Germany, with a 90-year history.
  • The company invested in Fujifilm’s Jet Press 720S in 2018 to be more cost-efficient and offer greater flexibility to customers.
  • Has now become first adopter in Europe of Fujifilm’s new FS-1 food-safe ink, used in combination with the Jet Press 720S.
  • Invested in the Jet Press 750S High Speed Model in late 2021, which has resulted in even more business growth.
  • Also use an Acuity B1 for large format packaging products.
  • Values their partnership with Fujifilm and considers their investment a success.

With our Fujifilm investments, we make significant savings on waste, downtime, and consumables, helping us and our customers to contribute to a more circular economy.

German Brodbeck | Ebro Color

Watch the Video

Based in Albstadt, southern Germany, Ebro Color is a modern, cardboard packaging print specialist with more than 90 years of history behind it. Founded in 1925, it has continually invested in new technologies over the years and now produces cardboard packaging and display units for a huge range of customers in a variety of sectors, from cosmetics to food, jewellery, and tourism. The business is run by brothers, and joint CEOs, German and Simon Brodbeck.

Back in 2018, though already something of a short-run specialist, offering run lengths as low as 25 units, the company decided to give itself even more flexibility and lower its costs further by making its first digital press investment. After a careful decision-making process, it chose to invest in the Fujifilm Jet Press 720S, after being impressed by its quality and reliability.

“The Jet Press 720S gave us the ability to offer ultra-short-run jobs (down to runs of one) both quickly and profitably, enabled us to produce high quality samples and prototypes, and to seriously target the end user market and move our business to an online model for the first time.” Explains German Brodbeck.

More recently, the company has become the first in Europe to use the Jet Press 720S with Fujifilm’s new FS-1 food-safe ink.

“In the past, we had to produce all food safe packaging for our customers on offset, regardless of run length.” continues Mr. Brodbeck. “Using the Jet Press 720S with Fujifilm’s food-safe ink has given us the option to produce food safe packaging products quicker, at a much lower cost, offering us the flexibility to produce both short and long run lengths. The press is much easier to use with significantly less downtime, and greater environmental benefits, so we could not be more pleased with the investment. One of our main concerns was if the quality of print produced on the press would be affected, but we were delighted that both the quality and reliability has remained the same and the difference to offset is undetectable.”

“We are using it to produce not only food packaging but also toy and cosmetic packaging, due to customer health and safety concerns and regulations surrounding these products. Ultimately, it is helping us to run our business more efficiently and take on a broader range of work.”

Additionally, Ebro Color invested in the Jet Press 750S High Speed Model in October 2021.

“Following the business success we saw after using the Jet Press 720S, we decided to invest in the 750S High Speed Model to keep up with growing customer demand. Our main reason for choosing this press was the output and large print volumes it could produce. It has enabled us to keep downtime to a minimum, especially during our peak season, and alleviated pressure elsewhere in the factory, allowing us to move many jobs from offset to digital.

“Another key reason for this investment was the sustainability benefits it offered. As a packaging business, sustainability is at the forefront of our customers’ minds. With our Fujifilm investments, we make significant savings on waste, downtime, and consumables, helping us and our customers to contribute to a more circular economy.”

Ebro Color also has an Acuity B1, which it is using to print large format packaging products.

“Typically, there are a lot of teething problems when a new press is installed, but with all of our Fujifilm investments, we were able to start using them out of the box, with seamless integration into our existing workflow. Communication with Fujifilm is excellent, and they are always readily available to support us. We’ve worked with Fujifilm for many years, and for both commercial digital and wide format solutions.“ Concludes Mr. Brodbeck.

“The first use of the food-safe ink in Europe represents decades of innovation from Fujifilm and marks an exciting time for the digital print industry.” Comments Taro Aoki, Head of Digital Press Solutions, Fujifilm EMEA. “We are delighted to see how the combination of the Jet Press and our food safe ink have been real game changers for Ebro Color’s business over the years. We are excited to be able to continue this long term partnership with Ebro and look forward to seeing what is next for them.”

Jet Press 750S High Speed Model

Find out more about how the quality and speed of the Jet Press 750S High Speed Model make it ideal for folding carton applications

Discover Jet Press

Case Study: Jet Press 750S HSM & 720S

Ebro Color

Case Study

Packaging printer Ebro Color benefits from multiple Jet Press installations, thanks to quality and food-safe ink.

Ebro Color

Albstadt, Germany

Jet Press 750S HSM & 720S

Highlights

  • Ebro Color is a cardboard packaging print specialist based in Albstadt, Germany, with a 90-year history.
  • The company invested in Fujifilm’s Jet Press 720S in 2018 to be more cost-efficient and offer greater flexibility to customers.
  • Has now become first adopter in Europe of Fujifilm’s new FS-1 food-safe ink, used in combination with the Jet Press 720S.
  • Invested in the Jet Press 750S High Speed Model in late 2021, which has resulted in even more business growth.
  • Also use an Acuity B1 for large format packaging products.
  • Values their partnership with Fujifilm and considers their investment a success.

It’s the partnership and the support that Fujifilm brings, and the value of having the backing of such a respected and established brand, that really clinched it for us.

Colin Le Gresley | Aztec Label

Watch the Video

Based in Kidderminster, West Midlands, Aztec Label is a family-run business that has supplied high quality self-adhesive label products to a huge range of customers for nearly 30 years. Company owner, Colin Le Gresley, founded the company in 1993, in his garage, and since then the business has grown rapidly.

Following recent investments in Fujifilm’s Flenex water-washable flexo plates and Sericol JJ LED UV inks, Aztec Label has now also invested in Fujifilm’s Activ LED UV curing system as part of a drive to more sustainable production. The new system was installed in October 2022.

“I’m always asking how we can do things better,” says Le Gresley. “Thirty years ago I was a flexo print operator and the reason I left the security of that job was that I had a vision for a company that did things differently.

“Giving our customers the best possible service and the best possible products has always been crucial to us and we’re always looking for the latest technological solutions to help us do that, not just today or in the next few years, but in the decades to come. My three sons all work in the business and I want to see it continue to thrive long after I pass it over to them.

“LED is the future – it’s about reducing our energy use and our environmental impact, and it’s about being more efficient. We’re in the process of converting all our production lines to LED curing, and in Fujifilm, we have a partner that offers not only multiple solutions, but also invaluable strategic support. Their Flenex plates are more reliable and more durable than the plates we were using before, and their LED-curable inks perform better on press than others we trialled. But more than that, it’s the partnership and the support that Fujifilm brings, and the value of having the backing of such a respected and established brand, that really clinched it for us.

“Fujifilm knows our market and our business, and they always put their hand up and take responsibility if there is an issue. Because of that, I trust their advice and I can see this being a successful partnership for many years to come.”

Andy Kent, Divisional Manager, Fujifilm UK says: “We’ve been delighted to work with Aztec for several years now. They’re an ambitious company looking to grow, and to do so in a responsible, sustainable way. This mirrors our approach exactly, and with our wide and growing range of analogue and digital solutions in this sector, the future possibilities are endless. We look forward to exploring that future alongside them.”

Activ LED UV System

Find out more about why the Activ LED Curing System can improve productivity and sustainability

Discover ACTIV LED UV Curing System

Case Study: Jet Press 750S HSM & 720S

Ebro Color

Case Study

Packaging printer Ebro Color benefits from multiple Jet Press installations, thanks to quality and food-safe ink.

Ebro Color

Albstadt, Germany

Jet Press 750S HSM & 720S

LED UV curing is the future, but not all LED systems are equal. We weren’t fully satisfied with our existing LED system, and with Fujifilm’s Activ system we’re seeing a productivity increase of around 30%, as well as better quality finished products.

Francesc Egea | IPE Industria Gráfica

Highlights

  • Ebro Color is a cardboard packaging print specialist based in Albstadt, Germany, with a 90-year history.
  • The company invested in Fujifilm’s Jet Press 720S in 2018 to be more cost-efficient and offer greater flexibility to customers.
  • Has now become first adopter in Europe of Fujifilm’s new FS-1 food-safe ink, used in combination with the Jet Press 720S.
  • Invested in the Jet Press 750S High Speed Model in late 2021, which has resulted in even more business growth.
  • Also use an Acuity B1 for large format packaging products.
  • Values their partnership with Fujifilm and considers their investment a success.

Based in Albstadt, southern Germany, Ebro Color is a modern, cardboard packaging print specialist with more than 90 years of history behind it. Founded in 1925, it has continually invested in new technologies over the years and now produces cardboard packaging and display units for a huge range of customers in a variety of sectors, from cosmetics to food, jewellery, and tourism. The business is run by brothers, and joint CEOs, German and Simon Brodbeck.

In Fujifilm we have a partner with both the ink and the curing solution to help us deliver better, faster results to our customers, while at the same time helping us to meet the ambitious sustainability goals we continually set for ourselves.

Francesc Egea | IPE Industria Gráfica

“Fujifilm’s Activ LED UV curing system, with the huge energy saving potential it offers, is just such a technology. We already had a very successful relationship with Fujifilm as a flexo ink supplier, so when we had some issues with our existing LED curing system and were looking for an alternative – it made sense on a number of levels to speak with Fujifilm. They’re now a ‘whole solution’ partner for us, giving us one point of contact for ink and for the curing technology if there are ever any issues.”

Aside from sustainability – important though it is – investment decisions also need to make business sense, as Mr Egea explains: “LED UV curing is the future, but not all LED systems are equal. We weren’t fully satisfied with our existing LED system, and in moving some of our sleeve and sachet production to Fujifilm’s Activ system we’re seeing a productivity increase of around 30%, as well as better quality finished products. The level of continuous investment required to remain competitive in our industry is an ongoing challenge,” Mr Egea concludes. “But in Fujifilm we have a partner with both the ink and the curing solution to help us deliver better, faster results to our customers, while at the same time helping us to meet the ambitious sustainability goals we continually set for ourselves.”

Manuel Schrutt, Head of Packaging, EMEA adds: “Fujifilm has a huge range of solutions for the flexo market, from inks and plates to curing systems, all of them designed to minimise waste and maximise profitability. We’re delighted to have expanded our existing relationship with IPE and look forward to a long continuing partnership.”

Activ LED UV System

Find out more about why the Activ LED Curing System can improve productivity and sustainability

Discover ACTIV LED UV Curing System

Discover more…

Learn more about Activ LED Curing System by downloading the product brochure

Download product brochure

╳

Digital print technology for a circular economy

This white paper has been published by Fujifilm as part of its commitment to deliver technically advanced and sustainable printing solutions for the print industry

Read the white paper

Reading time: 2 minutes

Where does print fit in the circular economy?

From books, newspapers, magazines and brochures to folders, annual reports and packaging, print remains a vital and highly effective branding, marketing and communications tool. But in an age of heightened environmental concern and ‘net zero’ carbon reduction targets, how can print be used in the most efficient and responsible way? In this white paper, we take a look at how the latest digital printing technology is dramatically cutting waste and making recycling much easier.

Download white paper

Fill out the form to download the full 12 page White Paper

Download the full 12 page White Paper here

╳

We must do more

As part of the “European Green Deal” project, there is an action plan for the EU to boost the efficient use of resources by moving to a clean, circular economy, restore biodiversity and cut pollution, and be climate neutral by 2050. To achieve this goal, action must be taken at all levels. Switching to renewable energy will, on its own, reduce global greenhouse gas emissions by only 55%. The remaining 45% of emissions come from the way we make and use products, which means working smarter and wasting less.

Fujifilm is committed to fully integrating print into the circular economy. Net zero doesn’t have to mean online only – print will always have a vital role to play, and we’re committed to making sure it can always play that role efficiently, effectively and sustainably.

The way we print is changing

The graphics industry has many analogue techniques which, especially when used for bespoke or short run work, have an enormous impact on the environment.

Now, thanks to the latest developments in digital print technology, there are machines which can print while also:

• Massively reducing raw material use
• Using fewer and more sustainable consumables
• Needing far fewer parts replacing
• Producing less waste
• Consuming less water
• Producing 100% recyclable printed products

This technology is moving print from the linear to the circular economy in which everyone has a role to play in keeping our planet liveable and our prosperity intact.

Digital print technology for a circular economy

This white paper has been published by Fujifilm as part of its commitment to deliver technically advanced and sustainable printing solutions for the print industry

Read the white paper

Reading time: 2 minutes

Where does print fit in the circular economy?

From books, newspapers, magazines and brochures to folders, annual reports and packaging, print remains a vital and highly effective branding, marketing and communications tool. But in an age of heightened environmental concern and ‘net zero’ carbon reduction targets, how can print be used in the most efficient and responsible way? In this white paper, we take a look at how the latest digital printing technology is dramatically cutting waste and making recycling much easier.

We must do more

As part of the “European Green Deal” project, there is an action plan for the EU to boost the efficient use of resources by moving to a clean, circular economy, restore biodiversity and cut pollution, and be climate neutral by 2050. To achieve this goal, action must be taken at all levels. Switching to renewable energy will, on its own, reduce global greenhouse gas emissions by only 55%. The remaining 45% of emissions come from the way we make and use products, which means working smarter and wasting less.

This certification program sets certain priorities to the certification criteria according to the product category and the use and features of each product through its entire life cycle. Fujifilm then clarifies the environmental value of each product by conducting environmentally conscious design assessments based on such certification criteria at the time of product development. Certain products are then selected for certification based on the total score of each assessment item. These products are reviewed and approved by the Group Certification Council, and finally certified as a Fujifilm “Green Value Product”.

The way we print is changing

The graphics industry has many analogue techniques which, especially when used for bespoke or short run work, have an enormous impact on the environment.

Now, thanks to the latest developments in digital print technology, there are machines which can print while also:

• Massively reducing raw material use
• Using fewer and more sustainable consumables
• Needing far fewer parts replacing
• Producing less waste
• Consuming less water
• Producing 100% recyclable printed products

This technology is moving print from the linear to the circular economy in which everyone has a role to play in keeping our planet liveable and our prosperity intact.

Certification ranking and criteria

Fujifilm classifies its products into three certification ranks (diamond, gold, and silver) according to the degree of their contribution to the reduction of environmental impact.

RankCertification criteria
DiamondProducts and services that user their respective industries’ innovative technologies to substantially contribute to reducing environmental impact
GoldProducts and services that reduce environmental impact at their respective industries’ highest level
SilverProducts and services that reduce environmental impact at a higher level than their respective industries’ standard

Product examples

In Fujifilm’s Graphic Arts business, the following products have been certified for their environmental performance:

Jet Press 750S High Speed Model:  GOLD

Effects on reduction of environmental impact:

  • Many of the consumables associated with conventional offset printing are eliminated
  • Significantly reduces the amount of wasted paper
  • Smaller footprint compared to previous models
  • The efficient drying mechanism reduces drying times, contributing to significantly higher speeds, and saving power
  • Excellent paper recycleability (de-inking ability)

Overall, there are significant reductions in resources, water use and waste compared to equivalent offset presses, with excellent paper recycling.

Revoria Press PC1120:                      SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

Revoria E1 Series:                             SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

Digital print technology for a circular economy

This white paper has been published by Fujifilm as part of its commitment to deliver technically advanced and sustainable printing solutions for the print industry

Read the white paper

Reading time: 2 minutes

Fujifilm’s Sustainable Value Plan 2030 (SVP2030)

The Fujifilm Group announced its Sustainable Value Plan 2030 (SVP2030) in August 2017. The new plan set targeting FY2030 as its long-term goal, which is expected to lay the foundations of the Group’s business management strategies for sustainable growth. One of the key pillars of the SVP2030 is dedicated to the environment.

Where does print fit in the circular economy?

From books, newspapers, magazines and brochures to folders, annual reports and packaging, print remains a vital and highly effective branding, marketing and communications tool. But in an age of heightened environmental concern and ‘net zero’ carbon reduction targets, how can print be used in the most efficient and responsible way? In this white paper, we take a look at how the latest digital printing technology is dramatically cutting waste and making recycling much easier.

We must do more

As part of the “European Green Deal” project, there is an action plan for the EU to boost the efficient use of resources by moving to a clean, circular economy, restore biodiversity and cut pollution, and be climate neutral by 2050. To achieve this goal, action must be taken at all levels. Switching to renewable energy will, on its own, reduce global greenhouse gas emissions by only 55%. The remaining 45% of emissions come from the way we make and use products, which means working smarter and wasting less.

This certification program sets certain priorities to the certification criteria according to the product category and the use and features of each product through its entire life cycle. Fujifilm then clarifies the environmental value of each product by conducting environmentally conscious design assessments based on such certification criteria at the time of product development. Certain products are then selected for certification based on the total score of each assessment item. These products are reviewed and approved by the Group Certification Council, and finally certified as a Fujifilm “Green Value Product”.

The way we print is changing

The graphics industry has many analogue techniques which, especially when used for bespoke or short run work, have an enormous impact on the environment.

Now, thanks to the latest developments in digital print technology, there are machines which can print while also:

• Massively reducing raw material use
• Using fewer and more sustainable consumables
• Needing far fewer parts replacing
• Producing less waste
• Consuming less water
• Producing 100% recyclable printed products

This technology is moving print from the linear to the circular economy in which everyone has a role to play in keeping our planet liveable and our prosperity intact.

Certification ranking and criteria

Fujifilm classifies its products into three certification ranks (diamond, gold, and silver) according to the degree of their contribution to the reduction of environmental impact.

Fujifilm has recently increased its target for contributing to reducing CO2 emissions generated in society from 50 million tonnes to 90 million tonnes.  The aim is to achieve this by replacing conventional products with products that are more sustainable.

So far (2020) the progress is 20 million tonnes, 23% of the way towards the target

Product examples

In Fujifilm’s Graphic Arts business, the following products have been certified for their environmental performance:

Jet Press 750S High Speed Model:  GOLD

Effects on reduction of environmental impact:

  • Many of the consumables associated with conventional offset printing are eliminated
  • Significantly reduces the amount of wasted paper
  • Smaller footprint compared to previous models
  • The efficient drying mechanism reduces drying times, contributing to significantly higher speeds, and saving power
  • Excellent paper recycleability (de-inking ability)

Overall, there are significant reductions in resources, water use and waste compared to equivalent offset presses, with excellent paper recycling.

Revoria Press PC1120:                      SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

Revoria E1 Series:                             SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

Promote the recycling of resources

Reduce the amount of water the Fujifilm Group uses by 30% by FY2030 (compared to FY2013 levels)

The result in FY2020 was 16%, so the company is over half-way towards the goal of 30% by FY2030.

Contribute to the treatment of 35 million tonnes of water per year in society by FY2030

The result in FY2020 was 8 million tonnes, so the company is around 23% of the way towards the goal of 35 million tonnes by FY2030.

Reduce the amount of waste produced by the Fujifilm Group by 30% by FY2030 (compared to FY2013 levels)

Fujifilm has managed to ensure that the amount of waste produced by the Group did not increase in FY2020, despite rising revenues and an expansion of the business, but has not yet managed to make the reductions planned.  This is a key area of focus for the future.

Achieve a recycling index*3 of more than 10 by FY2030 (was 6.5 in FY2020)

Achieve a valuables conversion index*4 of more than 1 in FY2030 (was 0.63 in FY2020)

*3 Recycling index = (Recycled volume + Valuable-converted volume) / Simple disposal volume

*4 Valuables conversion index = Valuable-converted volume / Recycled volume

Address energy issues towards a decarbonised society

By contributing to the creation and widespread use of renewable energies through advanced materials, Fujifilm aims to help address energy issues and the move towards a decarbonised society. In particular, a New Energy and Industrial Technology Development Organisation (NEDO) started the development of an “all solid state lithium-ion battery” – a next generation storage battery for electric vehicles, under an industry-government-academia collaboration. Fujifilm is participating in the project as one of 23 manufacturers of cars and batteries.

Ensure product and chemical safety

Under this objective, Fujifilm’s aim is to minimise the adverse effect of chemical substances on human health and the environment. In particular, Fujifilm completed the replacement of 2 of 7 chemical substances within the high priority substances for risk management, a new classification established in 2020.  In addition, Fujifilm held online briefings for business partners and achieved 90% understanding of the chemSHERPA chemical information communication system, contributing to further improvement of management accuracy for hazardous substances used in products.

Digital print technology for a circular economy

This white paper has been published by Fujifilm as part of its commitment to deliver technically advanced and sustainable printing solutions for the print industry

Read the white paper

Reading time: 2 minutes

Where does print fit in the circular economy?

From books, newspapers, magazines and brochures to folders, annual reports and packaging, print remains a vital and highly effective branding, marketing and communications tool. But in an age of heightened environmental concern and ‘net zero’ carbon reduction targets, how can print be used in the most efficient and responsible way? In this white paper, we take a look at how the latest digital printing technology is dramatically cutting waste and making recycling much easier.

We must do more

As part of the “European Green Deal” project, there is an action plan for the EU to boost the efficient use of resources by moving to a clean, circular economy, restore biodiversity and cut pollution, and be climate neutral by 2050. To achieve this goal, action must be taken at all levels. Switching to renewable energy will, on its own, reduce global greenhouse gas emissions by only 55%. The remaining 45% of emissions come from the way we make and use products, which means working smarter and wasting less.

This certification program sets certain priorities to the certification criteria according to the product category and the use and features of each product through its entire life cycle. Fujifilm then clarifies the environmental value of each product by conducting environmentally conscious design assessments based on such certification criteria at the time of product development. Certain products are then selected for certification based on the total score of each assessment item. These products are reviewed and approved by the Group Certification Council, and finally certified as a Fujifilm “Green Value Product”.

The way we print is changing

The graphics industry has many analogue techniques which, especially when used for bespoke or short run work, have an enormous impact on the environment.

Now, thanks to the latest developments in digital print technology, there are machines which can print while also:

• Massively reducing raw material use
• Using fewer and more sustainable consumables
• Needing far fewer parts replacing
• Producing less waste
• Consuming less water
• Producing 100% recyclable printed products

This technology is moving print from the linear to the circular economy in which everyone has a role to play in keeping our planet liveable and our prosperity intact.

Certification ranking and criteria

Fujifilm classifies its products into three certification ranks (diamond, gold, and silver) according to the degree of their contribution to the reduction of environmental impact.

Fujifilm has recently increased its target for contributing to reducing CO2 emissions generated in society from 50 million tonnes to 90 million tonnes.  The aim is to achieve this by replacing conventional products with products that are more sustainable.

So far (2020) the progress is 20 million tonnes, 23% of the way towards the target

Product examples

In Fujifilm’s Graphic Arts business, the following products have been certified for their environmental performance:

Jet Press 750S High Speed Model:  GOLD

Effects on reduction of environmental impact:

  • Many of the consumables associated with conventional offset printing are eliminated
  • Significantly reduces the amount of wasted paper
  • Smaller footprint compared to previous models
  • The efficient drying mechanism reduces drying times, contributing to significantly higher speeds, and saving power
  • Excellent paper recycleability (de-inking ability)

Overall, there are significant reductions in resources, water use and waste compared to equivalent offset presses, with excellent paper recycling.

Revoria Press PC1120:                      SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

Revoria E1 Series:                             SILVER

The requirements of major environment labels for energy consumption, hazardous substances, audible sound levels during operation and recyclable design are satisfied.

Since 2013, we’ve significantly cut back on the waste produced at our ink factory, and last year (2021), 689.7 tonnes of waste produced on site went for recycling.

Craig Milsted | Sustainability Advisor, Fujifilm Speciality Ink Systems

Promote the recycling of resources

Reduce the amount of water the Fujifilm Group uses by 30% by FY2030 (compared to FY2013 levels)

The result in FY2020 was 16%, so the company is over half-way towards the goal of 30% by FY2030.

Contribute to the treatment of 35 million tonnes of water per year in society by FY2030

The result in FY2020 was 8 million tonnes, so the company is around 23% of the way towards the goal of 35 million tonnes by FY2030.

Reduce the amount of waste produced by the Fujifilm Group by 30% by FY2030 (compared to FY2013 levels)

Fujifilm has managed to ensure that the amount of waste produced by the Group did not increase in FY2020, despite rising revenues and an expansion of the business, but has not yet managed to make the reductions planned.  This is a key area of focus for the future.

Achieve a recycling index*3 of more than 10 by FY2030 (was 6.5 in FY2020)

Achieve a valuables conversion index*4 of more than 1 in FY2030 (was 0.63 in FY2020)

*3 Recycling index = (Recycled volume + Valuable-converted volume) / Simple disposal volume

*4 Valuables conversion index = Valuable-converted volume / Recycled volume

Impressive waste reduction

“But it’s not only energy consumption that we have been targeting.  Since 2013, we’ve significantly cut back on the waste produced at our ink factory, and last year (2021), 689.7 tonnes of waste produced on site went for recycling.

“Other initiatives include: 100% of our raw materials packaging is reused and recycled; we return 1000 litre IBCs for cleaning and reuse, rather than disposing of them; and a number of moulded components used as part of our ink pouches are made from recycled materials. Additionally, we now secure our pallets with straps rather than using shrink wrap, which reduces our waste by around 8 tonnes annually. We are also in the process of swapping plastic tape for paper tape.

“In R&D we have also achieved a 50% reduction in glass jar testing; a 38% reduction in end container testing for one litre bottles; a 74% reduction in end testing for five litre cubitainers; and we have cut back on the use of one, two and three litre pouches by 29%, 33% and 20% respectively. We are literally looking at every single part of our operation and making changes to reduce our environmental impact.

Smart cutbacks on solvents

“Overall, thanks to the printers we sell becoming more technologically advanced over the years, less ink is required during the printing process.  This is obviously a better and more sustainable situation in itself. However, you can’t print without ink – it’s the most crucial element of printing. So for the inks that we produce at our factory, previously we would typically use around 140,000 litres of oil-based solvents to clean the vessels used in our ink-making and mixing equipment.

“However, very recently we replaced our oil-based solvent cleaner with an 80% water-based (aqueous) cleaning solution, manufactured by a company called Safe Solvents. Coinciding with this, a first-of-its-kind pot washing machine, also supplied by Safe Solvents, was installed at the factory.

“Suitable for use with the new aqueous cleaning solution, the machine offers a significantly more efficient pot washing solution on our site. The aqueous cleaner and pot wash machine combo makes it possible for us to separate solvent and aqueous waste, and in the future, it could enable us to reuse the pots after they have been cleaned, and then when they are beyond reuse, have the clean plastic shredded and sent for further recycling.

Measuring and analysing is key

“The recently installed pot washing machine at Broadstairs is a world-first, so we look forward to reviewing our credentials in the future and seeing the difference it has made. The most important thing is that we continue to measure and analyse everything, as only by measuring can you improve.

“It really is a painstaking, but ultimately very rewarding process – we have achieved a great deal in the last 12 months with our renewed focus, but we are confident we can continue to make iterative improvements all over the site, across all areas of energy, waste and material reductions, to make this award-winning factory a world-class, sustainable one too.”