Alluring? Closed loop recycling for lithographic aluminium

Alluring? Closed loop recycling for lithographic aluminium

AGFA GRAPHICS
Alluring?
Closed loop recycling for
lithographic aluminium ?
Peter Verschave
IFEST 2012
16 Februari 2012
Agfa Graphics in the Agfa-Gevaert Group
GLOBAL TURNOVER 2010
2.9 billion euro
53%
AGFA GRAPHICS
40%
AGFA HEALTHCARE
7%
AGFA MATERIALS
Agfa Graphics
2/28/2012
2
Our Customers
Commercial
printers
software
Newspapers
Packaging
services
printers
complete
solutions
Sign & display
printers
consumables
hardware
Agfa Graphics
2/28/2012
3
Our main Technologies
INDUSTRIAL INKJET
different Ink technologies
UV–LED curing
quality, speed, alternative printing technology
PREPRESS
workflow sw, equipment, film, plates, chemistry
shift from analogue to digital prepress
shift toward more efficiency and ecology
Agfa Graphics
2/28/2012
4
Our position in the printing industry
Creation
Pre press
Printing and finishing
Text
Editorial
Process
Page
Layout
Preflight
Proofing
Plate-making
Printing
Finishing
Images
Advertising
5
Agfa Graphics
2/28/2012
5
Offset printing
Agfa Graphics
2/28/2012
6
Planet
Our Products
Our Customers
People
Our World
Profit
Agfa Graphics
Our Operations
2/28/2012
7
Our World
Sustainable Development
for a
Sustainable Print Business
Agfa Graphics
2/28/2012
8
Our World
2 levels to reduce our
environmental footprint:
Agfa’s performance worldwide:
Water Usage
-27.0%
How we manufacture and
distribute the product
CO2 Emissions
-42.8%
Energy Usage
-22.4%
The way how the product is
used by our customers
VOC Emissions
-73.3%
ISO14001, OHSAS18001 & ISO50001
Worldwide SER-Programme
Packaging & logistics programmes
Agfa Graphics
2/28/2012
9
Our World
Sustainable Product Development
2 levels to reduce our
environmental footprint:
Customers’ performance:
How we manufacture and
distribute the product
Water Usage
The way how the product is
used by our customers
Energy Usage
CO2 Emissions
VOC Emissions
Cost impact
Ease of Use
Process stability
Product life cycle assessment studies
Agfa Graphics
2/28/2012
10
-10.0%
-20.0%
Human toxicity
Ozone depletion
0.0%
Fossil depletion
Metal depletion
Water depletion
Natural land
transformation
Urban land occupation
Agricultural land
occupation
Marine ecotoxicity
Freshwater ecotoxicity
Terrestrial ecotoxicity
Marine Eutrophication
Freshwater
eutrophication
Terrestrial acidification
Particulate matter
formation
Photochemical oxidant
formation
-30.0%
Climate change
LCA impact categories for 1m2 of newspaper
100.0%
90.0%
80.0%
70.0%
EoL treatment
(non-recylced)
60.0%
EoL collection
50.0%
Distribution
40.0%
Printing
30.0%
Prepress
20.0%
Paper
(printing)
Ink
(printing)
10.0%
Chemicals
(printing)
LCA impact categories
LCA study by Vito,Agfa
commissioned
by Corelio, Febelgra
& Agfa11
Graphics
2/28/2012
LCA impact categories for 1m2 of N94VCF
2/28/2012
12
LCA study by Vito, commissioned
by Agfa
Agfa Graphics
Example: climate change impact
Agfa Graphics
2/28/2012
13
Example: climate change impact
12.00
Agfa- and Prepress process steps
10.00
8.00
6.00
4.00
2.00
Agfa Graphics
P9
os
ta
r
70
Th
er
m
n7
rg
yE
li t
e
En
e
lu
m
Co
Vi
ol
et
N9
2
VC
F
N9
2
n2
lu
m
Co
Az
ur
a
0.00
Am
ig
o
Carbon footprint (in kg CO2-eq./m² plate)
Production of Litho aluminium base
2/28/2012
14
Example: climate change impact
12.00
Agfa- and Prepress process steps
10.00
8.00
6.00
4.00
2.00
Agfa Graphics
P9
os
ta
r
70
Th
er
m
n7
rg
yE
li t
e
En
e
lu
m
Co
Vi
ol
et
N9
2
VC
F
N9
2
n2
lu
m
Co
Az
ur
a
0.00
Am
ig
o
Carbon footprint (in kg CO2-eq./m² plate)
Production of Litho aluminium base
2/28/2012
15
Climate change exclusive the Al production
Agfa Graphics
2/28/2012
16
Use at the printer
Agfa Graphics
2/28/2012
17
Example: climate change impact
12.00
Agfa- and Prepress process steps
10.00
8.00
6.00
ca. 80% of the impact
4.00
2.00
Agfa Graphics
P9
os
ta
r
70
Th
er
m
n7
rg
yE
li t
e
En
e
lu
m
Co
Vi
ol
et
N9
2
VC
F
N9
2
n2
lu
m
Co
Az
ur
a
0.00
Am
ig
o
Carbon footprint (in kg CO2-eq./m² plate)
Production of Litho aluminium base
2/28/2012
18
Aluminium = 80% of the PCF of a plate
• Avoid losses in production and supply
• Look for alternatives
• Keep recyclability to a high level
• design for recyclability
• Choose your supply partners i.f.o. sustainability criteria
• Price; Quality; Energy consumption; Logistics; Waste mgmt; CSR
performance , …
• Help your customers with the resulting Al scrap management
• More efficient use of the aluminium
• Cradle 2 Cradle use of the aluminium
Agfa Graphics
2/28/2012
19
Aluminium wiki corner
•
third most abundant element in the earth's crust (7.3% by mass)
•
“young”metal
• 1808: existence first established
• 1854: saw the development of a viable, commercial production process
• Today: largest volume non-ferrous metals produced
•
•
Compared to copper, lead and tin: in use for thousands of years
“unique” metal
• strong, durable, flexible, impermeable, light-weight, it does not rust
• the Al2O3 surface layer hard, porous and hygroscopic
•
cfr. wet offset mechanism
Agfa Graphics
2/28/2012
20
Offset printing plate
Developed printing plate
AA1050
Electrograining
Exposed printing plate
Anodising
Light sensitive coating
Pre-press Production
Plate Manufacturing
Agfa Graphics
2/28/2012
21
Basic principle wet offset print
Hydrophilic Al2O3 layer
H2O
ink
H2O
H2O ink H O ink
2
ink
H2O
ink
ink
Image layer
Agfa Graphics
2/28/2012
22
Aluminium wiki corner
•
third most abundant element in the earth's crust (7.3% by mass)
•
“young”metal
• 1808: existence first established
• 1854: saw the development of a viable, commercial production process
• today: largest volume non-ferrous metals produced
•
•
Compared to copper, lead and tin: in use for thousands of years
“unique” metal
• strong, durable, flexible, impermeable, light-weight, it does not rust
• the Al2O3 surface layer hard, porous and hygroscopic
•
•
cfr. wet offset mechanism
can be reused endlessly
• ca. 75% of all aluminium ever made remains in use today
• represents a growing ‘energy and resource bank’
•
•
Long life cycle applications (eg. building)
Short life cycle applications (eg. packaging , printing plates)
Agfa Graphics
2/28/2012
23
Aluminium production 2010
Aluminium production 2010:
45 mio ton primary Al ww
7.7 mio ton secondary Al ( ca. 15% ww)
11.7 mio ton Europe (ca. 33% recycled Al)
Source: http://www.alueurope.eu/?page_id=1528
Agfa Graphics
2/28/2012
24
End uses of aluminium
Ca. 555 kton litho Al / year ww
ca. 1.0 % litho Al vs. ww Al demand (prim. & sec.)
ca. 1.2 % litho Al vs. ww primary Al production
Source: http://www.alueurope.eu/?page_id=1528
Agfa Graphics
2/28/2012
25
Cradle 2 Cradle litho aluminium
•
Feasibility study
•
•
•
•
•
Technical
Business
Logistics
LCA impact
Partners
+ litho aluminium supply- and scrap partners
•
Project approved within the 3rd programme of MIPVlaanderen
•
Project name: Alluring?
Agfa Graphics
2/28/2012
26
Current product flow
Lithographic Al manufacturer / roller
Al plate producer
offset plates
LME
Primary
Aluminium
New Al
(100%)
• Degreasing
• Graining, anodizing
• Surface treatment, coating
• Cutting and packaging
Rolled Al
Waste Al
with IL-paper
High value
Alu scrap
Other Al
applications
(downcycling )
Used plates
External
scrap collector
Al Recycling
Remelting and
alloying
Printer
Al scrap from other
sources
Agfa Graphics
2/28/2012
27
Alluring? concept and project partners
Agfa Graphics
2/28/2012
28
Alluring?
•
Start: 1st of May 2011
•
•
Technical and quality focus
Strong business plan and financial focus
• Litho Al scrap
•
High purity metal
•
Low in impurities from the use during the life cycle
–
•
Image, Al2O3 , and residues of ink, fountain and plate cleaner (evt.)
•
Correction of Al levels in other alloy scrap streams
•
High scrap value
•
Existing, efficient scrap logistics and recycling business
•
Ratio primary Al vs. available Al scrap (ww and in EU)
LCA impact
• Difficult to predict
• C2C recycling vs. downcycling
• Product supplier takes control and responsibility of the EoL
Agfa Graphics
2/28/2012
29
Agfa Graphics
2/28/2012
30