best practice analysis and results from graphic arts companies on energy management

EIE/06/075/SI2.448796 From January 2007 to March 2009

European Conference on energy efficiency in the graphic media industry

March 27 2009 BUW - Bergische Universität, Wuppertal

Best practice analysis and results from graphic arts companies on energy

management

Dr. Anastasios E. PolitisDr. Anastasios E. [email protected]

Athens Technological Educational Institute - ATEIAthens Technological Educational Institute - ATEI

EIE/06/075/SI2.448796 From January 2007 to March 2009 2

eeei Project partners• ATEI - Athens technologiacl Educational InstituteATEI - Athens technologiacl Educational Institute

• Bergische Universität Wuppertal Bergische Universität Wuppertal

• ENERGO GROUP AE ENERGO GROUP AE

• Energy Experts InternationalEnergy Experts International

• ENVIROSENVIROS

• Handwerkskammer MünsterHandwerkskammer Münster

• Heves Heves CountryCountry Chamber of Commerce and Industry Chamber of Commerce and Industry

• KVGO DienstencentrumKVGO Dienstencentrum


Project Objectives I

• Enhance awareness on energy and environmental issues

• Establish in-depth knowledge about energy efficiency within the European Graphic Arts and Media Industry

• Eliminate still existing barriers concerning efficiency improvement

• Tailor tools exactly fitted to the graphic arts and media sector

3


Project Objektives II

• Enable direct annual emission and costs reduction

• Reduce the CO² output about 2.500t and save an overall sum of 500.000€ in energy costs including ~100 SMEs until December 2008

4


Project Activities

• EU and Country-wide Inventory – Regulations and Tasks– Energy Consumption– Questionnaire Evaluation

• Tool generation

• EU wide Workshops

• Final European Conference

5


Energy management issues for the graphic arts and media

companies• Specific energy matters for the companies.• Production cooling / heating.• Energy consumption for compressors.• Energy reduction for “stand-by” production operations. • Energy consumption for VOC cleaning.• Use of renewable power resources (solar and

photovoltaic systems, windmills etc.) at company level.

MAIN ISSUES: • Energy use, consumption and costs remains often

“hidden”.• Energy consumption and costs are not taken as

important by the company.


Classification of graphic arts Classification of graphic arts companies within the projectcompanies within the project

Sheet-fed offset

Web-fed offset

• Flexographic printing

• Gravure printing

• Silk-screen printing

• Digital printing

• Book binding


Use of printing technologies among the graphic arts companies - EU wide

Results: Q - Analysis


Use of printing technologies among the graphic arts companies in the 5 project countries



Awareness of graphic arts companies Awareness of graphic arts companies on energy and environment issueson energy and environment issues

• Survey among companies in the 5 project countries

• Structured questionnaire with 22 questions in 3 main fields:

• General and specific on energy use, cost and consumption

• Management and energy strategy within the companies

• Aims for energy efficient management• Answers from 67 companies in the 5 countries


Results: Q - Structure


Results on graphic media companies from the survey

Country Number of companies per country

Total employees number

Average employees at companies per country

CZ 8 378 47 DE 19 1201 75 GR 14 566 40 HU 8 1180 147 NL 18 1208 67 Total 67 - -


Classification of the companies according to the use of printing

technologies

Technologies used

CZ DE GR HU NL Total

Sheet-fed offset

6 17 9 6 13 51

Web-offset 4 6 0 1 2 13 Flexography 1 2 3 2 1 9 Gravure 0 0 3 2 1 6 Silk screen 0 2 2 0 2 6 Digital printing

5 11 6 3 8 33

Book binding 7 6 10 2 5 30


Specific data of the 14 Greek companies surveyed

Technology Numbers of companies

Percentage

Sheet-fed offset

9 64.2%

Web- offset 0 0% Flexography 3 21.4% Gravure 3 21.4% Silk-screen 2 14.3% Digital printing

6 42.9%

Book-binding

10 71.4%


Combinations of production structures in the Greek

companies Technol ogy Number of

Companies Percentage

Sheet-fed offset + digital printing

3 21.4%

Sheet-fed offset and digital printing + Book-binding

3 21.4%

Sheet-fed offset printing + Book-binding

8 57.2%

Flexographic + Gravure printing

3 21.4%


Number of employees in the 14 Greek companies

Number of employees

Number of companies

Percentage

0-25 10 71.4% 26-50 1 7.15%

51-100 1 7.15% 101-150 1 7.15% 151-200 1 7.15%

Total 14 100%


Classification of companies according to the number of employees - Comparison between Greece and Germany

1 - 9 10 - 49 50 and more

GermanyGreece

0

10

20

30

40

50

60

70

80

90

100

Per

cen

tag

es

Number of employees

Distribution of enterprises acording to the number of employees


Results I: well-informed companies on energy management in the 5 project countries

0

10

20

30

40

50

60

70

80

90

100

Per

cen

tag

es

CZ GER GR HU NL

Percentages of the companies that are well-informed about energy efficiency possibilities in the different countries



Results ΙΙResults ΙΙ

• Bigger companies are in general better informed on energy management issues.

• Packaging printing and web-fed offset companies are also better informed on energy management issues.

• A large number of companies is nor aware about energy costs in the company (this is the case in Greece).

• Energy efficiency management appears as a necessity for micro and small graphic arts companies

• All data are located in the European Synthesis Report Graphic Media), www.eeei.info.


European Synthesis Report Graphic Media www.eeei.info


Issues for management and actions on Energy efficiency from graphic-media

companies I • More information on energy matters is required since

energy is not amongst their main concerns. • No staff member for handling energy matters. • No energy saving information provided to the staff. • Certain companies have developed loose (non

systematic) energy saving measures. • Energy consumption is indeed a matter on machinery

investments • EMAS certification is known to some of the companies

but only one of them is EMAS certified. • ISO-14001 certification is widely known to the companies

- One third of the Greek companies are ISO 14001 certified.

• Many companies intend to develop either EMAS certification or tISO-14001 certification.



companies II• Companies are generally NOT aware on yearly energy consumption

and costs.• Lack of awareness on the issue of energy consumption. • Energy costs are included in general expenses and are not associated

with production output. • Difficulties in providing information about total energy consumption

per amount of production volumes. • Particularly important: Different methods for measuring production

output are used by the companies.• Combination of production and material costs is the most favourable. • In general: Sheet-fed and digital printing companies transformr the

various printed products in number of printed sheets ( in a certain dimension).

• Transformation of this production value into number of m2 of printed surface

• Getting specific consumption values concerning energy from companies: A difficult task

• The expressed interest on efficient energy management needs to be turned to real actions.



companies III

• Particularly important: Different methods for measuring production output are used by the companies.

• Combination of production and material costs is the most favourable.

• In general: Sheet-fed and digital printing companies transform the various printed products in a number of printed sheets per year (e.g. in 70 x 100 cm)

• Transformation of this production value into number of m2 of printed surface.

• Silk-screen companies provide data by number of printed jobs.

• Flexo and gravure (flexible packaging printing substrates) provide production output in Kg.


Lessons learned from pilot companies on Energy efficiency

• Energy savings has a good potential in the graphic arts SME’s

• Energy should be certainly a matter of daily practice in the companies

• Energy should be a matter of management within the company operation.

• Application of a system for environmental management

• Certifications according to EMAS / ISO-14001• Energy as an important factor on investment

decisions.


The Challenge for awareness and concrete actions from the European Graphic arts and media Industry for

the reduction of energy consumption

• Together we can make graphic media industry proud for its responsible commitment for a better environment and use of less energy recourses …

• … a necessity for our common future!


We have started!

• Cooperation with the Hellenic Federation of printing companies - SEMEE

• National workshop in Greece 9 March 2009

• Brochure on Energy efficiency, the EEEI project and the E-BAG tool in Greece

• Establishment of consultancy actions

• Next activity of the Greek EEEI partners ATEI and ENERGO GROUP SA: participation at the Greek graphic arts and Packaging exhibition GRAPHICA 29 May - 2 June 2009, in Athens


The EEEI brochure in Greek


The national workshop I


The national EEEI Workshop II


Thank you very much for your Thank you very much for your attentionattention!!

Dr. Anastasios E. PolitisDr. Anastasios E. Politis

[email protected]@techlink.gr

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best practice analysis and results from graphic arts companies on energy management

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