Eco balance

One way to check and co-ordinate the elements of our environmental policy, as well as measuring progress, is the Eco Balance, which has been operational throughout RSDB since 1994. The Eco Balance is a mass balance of all inflows and outflows and has displayed a clear, continuous improvement in recent years, compared with 1994, the reference year. Thanks in particular to improvements in our process management, we have achieved a year-on-year improvement in our environmental performance on virtually every front. A more accurate picture is gained by comparing results for the previous five years. Our figures are based on the most recent results as of March 2007. Corrections to earlier publications have been incorporated.

The data produced by RSDB are coordinated and validated by TME – the Institute for Applied Environmental Economics – which specialises in the economics and management of the environment and natural resources.

The Ecobalance measures the streams in the individual RSDB plants

and the group as a whole. It is not just a record. If performance is accurately captured in terms of numbers, it becomes possible to set precise goals with plans for action, the results of which can also be precisely measured. Because the Ecobalance reveals the companies’ complete material budget, it can be

used not only to manage emissions but also to help in the efficient management of raw materials and ancillary chemicals in the production process.

Explanatory notes to the 2007 charts:

WATER

RSDB's water consumption (m3/tonne paper input)

Water consumption per tonne of paper input has declined slightly since 2006.

Since 2003 it has dropped by 20%.

ENERGY

RSDB's energy consumption (Gigajoule/tonne paper input)

The energy consumption figure includes all energy consumed:

electricity, gas and district heating. Just as in 2006, 2007 saw a drop in energy consumed per tonne of paper input. We can see a cut of 12% below the 2003 figure. This index is sensitive to the trend towards printing on thinner paper, which

leads to a larger number of press rotations (machine hours and thus energy consumed) per unit weight of paper that enters production. In 2007, however, RSDB has been able to compensate thanks to constant attention to energy consumption.

Great strides have been made here, as by investing in concentration controlled extraction above the presses and the use of high-pigment inks (less extraction power needed due to lower solvent concentrations). Further optimisation of toluene

recovery in rotogravure, paper shrinkage compensation and revealing the use of stand-by electricity (and cutting it back) delivered considerable savings. Relatively minor, but nonetheless important matters also received attention, such

as switching off compressed air if production is still for a time in afterpress.

EMISSIONS

 RSDB's emissions of VOC to air (kg/tonne paper input)

Roughly 28% of the total quantity of VOC (Volatile Organic Compounds) in 2007 consists of isopropyl alcohol (IPA). Other VOC emissions relate to volatiles from other moistening water additives, cleansers, and toluene from printing ink, together

making up approximately 58% (2007) of the total mass of VOC.

The trend of previous years has continued in 2007 as VOC emissions per tonne paper input have declined yet again, by 45% in total compared to the 2003 level.

In the offset plants, IPA and other moistening water additives account for approximately 89% (2007) of all VOC emissions. The measures taken to reduce IPA consumption in the offset plants led in the late 1990s and early 2000s to roughly a

halving of the emission of this compound per tonne of paper input to these plants. In recent years we have been exploring the bottom limit of this IPA dosage. In the RSDB offset plants the use of IPA per tonne of paper input has declined slightly in

2007 in comparison with 2006 (3%).

Aggregated toluene emissions per tonne of paper input to the rotogravure plants declined by around 22% in 2006. This had a number of causes: the deployment of a new press, use of high-pigment inks, and concentration controlled air extraction.

High pigment inks have a higher solids content (the pigment), so the ink layer laid down on the paper is thinner than it used to be, which in turn means that less toluene flows to the recovery unit. This delivers not just lower toluene emissions, it also lessens water and energy consumption because less toluene has to be recovered from the extracted air. In 2007, concentration controlled air extraction around the presses was taken further, so the extraction depends on the toluene concentration in the printed matter. Toluene recovery was also further optimised in

the reporting year.

ANCILLARY AND PROCESS MATERIALS

Besides raw materials (chiefly paper and ink), RSDB distinguishes

between ancillary and process materials.

 RSDB's consumption of ancillary materials (kg/tonne paper input)

Ancillary materials include such things as binding material, such as wire and glue, other adhesives and packaging, which make up very roughly 95% of the total weight of auxiliary materials used within RSDB.

In 2007 the consumption of ancillary materials per tonne of product declined a little from 2006. This goes against the tide of rising demand for printed matter

packaging. RSDB plants do attempt to counter adverse trends, partly by encouraging the use of multi-trip pallets, using thinner film and improvements in the packaging line (such as automatic control and even more custom-tailored packaging). The plants are dependent on their customers’ demands, but prefer to search together with them for savings options.

RSDB's consumption of process materials (kg/tonne paper input)

Process materials include chemicals (about 35% of the total mass), plates and the associated developer and fixer, cleaning cloths, cleansers and disposable packaging of products supplied to us. Process material consumption is strongly influenced ‘from outside’ as a result of the order package and order portfolio (colour use, colour changes, print run, paper types, etc.), since these determine the number of plates and the quantity of cleaning materials needed. If process management remains at a constant level, then a trend towards smaller print runs and the selection of thinner types of paper leads (among other things) to a larger number of offset plates per tonne of paper input.

For a number of RSDB plants, the effects of market demand in 2007 outweighed the beneficial effects of their own efforts at economising on process material consumption. The RSDB plants remain committed to an aware, efficient use of process materials.

WASTES

RSDB's recyclable waste materials (kg/tonne paper input)

Recyclable wastes comprise mainly paper and card.

The quantity of recyclable waste per tonne of paper input was higher in 2007 than 2006, influenced mainly by paper losses. Just as in previous years, in 2007 RSDB plants have devoted themselves to further cutting paper losses (paper used in the run-up phase, when no usable product comes off the press). This index, though, is also influenced by other, more incidental factors, such as rolls of old stock that were disposed of at one plant. In 2007, too, recyclable waste was released as a result of rebuilding. Finally, the index is influenced by efforts at waste separation, partly by retaining bundle banding for recycling, thus keeping it out of the ‘general process waste’ stream.

RSDB's general process waste (kg/tonne paper input)

The quantity of general process waste per tonne of paper input rose above the

2006 level. The plants worked continuously to limit the amount of process waste and have been successful in their efforts. Better waste separation at source, such as collecting synthetic oil and bundle banding for recycling, gave good results at a number of plants. Nevertheless, it was unusual circumstances that governed the picture. For example, one plant produced a large amount of packaging timber, used to protect parts of a new press. Furthermore, many plants were rebuilding internally, and the waste situation at one plant was drastically influenced as a sealing, banding and addressing business was once again brought within the gates. Work is always continuing on cutting waste by separating and recycling as much waste as possible.

RSDB's hazardous waste (kg/tonne paper input)

The quantity of hazardous waste per tonne of product in 2007 was a little higher than in 2006. This index is not entirely in RSDB’s hands. For instance, one plant processed a larger number of small orders, one of the effects being that more empty ink cans had to be taken away as hazardous waste.

Contact: emily.knegtel@rsdb.com