Digitally Printed Newspapers: Unrecyclable Trash or still a Sustainable Resource?

Transcription

1 Digitally Printed Newspapers: Unrecyclable Trash or still a Sustainable Resource? Axel Fischer International Association of the Deinking Industry (INGEDE) NIP23 21 September 2007 Anchorage The Water Example Now it is out. Water in plastic bottles has been hip.

2 Ban The Bottle The Water Example It took a long time to realize that shipping plastic bottles with water from Italy to the US is not sustainable. Sooner or later this will happen to digital prints. Unrecyclable prints will not sell in the long run. The further the technology has developed, the stronger the backlash will become.

3 Outline Who is INGEDE? What is paper recycling? Why digitally printed newspapers? What is the problem about it? What has been done? What can be done in the future? Who is INGEDE? International Association of the Deinking Industry, founded in 1989 A non-profit organization of paper mills utilizing recovered paper

4 Who is INGEDE? Currently 40 mills and research departments Representing more than 10.5 million tons of recovered paper per year Who is INGEDE? The members Cartiere Burgo S.p.A., Italy,Belgium Dalum Papir A/S, Denmark Holmen Paper AB, Sweden, Spain Leipa Georg Leinfelder, Germany Lenzing AG, Germany M-Real New Thames Ltd, UK Myllykosky Continental Group Lang Papier GmbH, Germany MD Papier, Plattling, Germany Papierfabrik Utzenstorf, Switzerl. Rhein Papier GmbH, Germany Norske Skog Group Bruck GmbH, Austria Golbey S.A., France Parenco B.V., Netherlands Skogn Mill, Norway Steti Mill, Czech Republic Packages Ltd., Pakistan Palm KG, Germany Papierfabrik Hainsberg, Germany Perlen Papier AG, Switzerland SCA Hygiene Products Consumer SCA Hygiene Products Away from Home, Germany Steinbeis Temming, Germany Stora Enso Group Hylte AB, Sweden Langerbrugge N.V., Belgium Maxau-Wolfsheck Mills, Germany Sachsen Mill, Germany Keräyskuitu OY, Finland UPM Group, Helsinki Augsburg Mill, Germany Chapelle Darblay, France Kaipola Mill, Finland Schongau Mill, Germany Schwedt Mill, Germany Shotton Mill, Germany Steyrermühl AG, Austria

5 What is paper recycling? A newspaper is the prototype of a recylable product. The consumer knows that newspapers are made from old paper. No other product is like this. Paper recycling means producing bright paper from bright paper not just board.

6 Paper recycling What happens with the paper? It has to be recycled. Not thermal. Not for board. But for new graphic paper.

7 (Source: KBA)

8 Inkjet: Kodak Versamark a capacity of up to one million impressions per day yielding more than 2,000 pages per minute Inkjet Newspapers In 1990, newspapers were produced on-demand via fax machines, but were gray, curly editions with limited success Scitex's PressPoint system was released, using satellite transmission technology to make remote, multicolor printing on tabloid-plus page size and full-color printing on sturdy, white stock paper possible to deliver newspapers on-demand. (Wikipedia/Scitex)

9 Kodak Versamark Digitaldruck Bayerlein is claimed to be the first company in the world to use the Newspaper Printing System, based on the Versamark VX5000. Earlier this year, the company began production of digitally printed, fourcolour newspapers for foreign publishing houses. ( Oct 10, 2005) Kodak Versamark In 2007, KODAK VERSAMARK Printing Systems will top 90 billion black and white and color A4 impressions through a combination of full page document production, partial page or hybrid printing, and address imaging. (Kodak Press Release Sept 10, 2007)

10 Kodak Versamark Chicago Tribune KODAK Microzone Publishing Solution There is a synergy between the various technologies ( ) that can be deployed by newspapers to take advantage of the strength of digital printing in producing highly personalized and short print runs in an economical manner, said H. Jack Knadjian, Vice President Publishing Market Segment, Kodak (Kodak Press Release Sept 10, 2007) Miyakoshi Printing Machinery Co., Ltd. Newspaper producing method US Patent Issued on November 23, Ink-jet printer arrangement for printing both sides of a web An apparatus is operable to print both sides of a web using two sets of ink-jet printers. A first set of printers are aligned horizontally, and so are the second set, with a vertical spacing between the first set and the second set.

11 IBM, Ricoh; Riso Ink Jet combined As regards the integration of digital printing processes into offset presses, KBA was the only manufacturer to date to show, at drupa 1995, the integration of Scitex (today Kodak Versamark) ink-jet heads into the superstructure of an Express press and the black imprinting of constantly changing caricatures into a four-colour offset newspaper.

12 EP/dry toner: History 2001: First digital print site of Océ at Wembley (London) - Danish daily newspaper Borsen - Swiss daily newspaper NZZ 2002: Financial Times in South Africa 2002: The Toronto Globe and Mail and Asahi newspaper group are the first newspapers from across the Atlantic to print digitally in London. 2005: The New York Times has started printing its national edition in London. August 2004: On-Demand Newspapers Go for the Gold in Athens How It Works Newspaper pages arrive as PDF files. Printing is accomplished by combining digital color, using the Xeikon, and digital monochrome, using the Nipson, on newspaper stock. Final printed newspapers are picked up for distribution according to a plan developed by each newspaper. The number of pages in the final publications, will vary per customer and will be defined by the individual customer.

13 Océ Digitally Printed Newspaper Better Than Offset With print quality claimed to be 'even better than offset', Oce systems have printed ( ) digitally in full colour. Financial Times, Guardian and Sydney Morning Herald, Spanish newspaper El Pais, Germany's Mitteldeutsche Zeitung. Océ Each day Océ produces a total of more than 5,000 international editions around 15 different titles at six separate commercial print sites in London, New York, Los Angeles, Sydney, Singapore and Zurich. (June 2007)

14 NewspaperDirect ND newspapers are digitally laser printed. This means that the resolution quality greatly exceeds standard newsstand copies. With crisp text and images, the quality is excellent and the ink doesn't smudge or rub onto a reader's fingers. Where does it all go?

15 Can Digital Prints Be Recycled? Do digital prints have to be recycled? No: if they go to the trash anyway Yes: if they are likely to be recovered Do digital prints have to be recycled? No: Photos, Large Format, Maybe: Manuals, Calendars Yes: High Volume - Direct Mail - Brochures - Newspapers

16 Consequences Do we need other collection systems? Or additional ones? Can the recycling process be changed? What is deinking? Generally: Removal of printing ink during the paper recycling process Cost effective and sustainable source of fibers for graphic papers (and hygiene papers)

17 Deinking Chemistry & Physics Deinking Chemistry & Physics

18 Deinking Chemistry & Physics Recovered paper is pulped Chemicals support the ink detachment: NaOH increases ph fibres swell and release ink Na 4 SiO 4 supports agglomeration, ph What is flotation? Separation of hydrophobic ink from hydrophilic fibers Air is blown into mixture of fibers, water and chemicals Foam transports hydrophobic particles to the surface Foam with ink is skimmed off

19 What is flotation? What is flotation?

20 What is flotation? Consequence for printing ink Ink has to be hydrophobic particle > 150 µm = screenable (stiff!) 30 µm < particle < 300 µm = cleanable 10 µm < particle < 100 µm = flotable particle < 10 µm = problem Problems with water based inks!

21 Deinkability of ink jet inks Pigment based black ink jet prints are neither deinkable nor bleachable. Dye based black ink prints are more or less efficiently colour stripped, depending on the dye formula. 10 % black ink jet printed papers in a wood-free or wood-containing furnish result in inacceptable brightness loss. Deinkability of ink jet inks Colored ink jet prints are mostly not deinkable Sometimes efficient color stripping with chemicals like hydrosulfite or ozone for magenta, cyan Yellow shade persists even ozone

22 Different types of inks UV inks: unacceptable specks, also Liquid toner: large visible specks Hot melt based ink jet inks lead to sticky deposits Water based pigment inks do not float, spoil in low amounts Dry toners mostly good recyclable What can we do?

23 What can we do? INGEDE Project Recyclability of Digital Prints Cooperation with digital industry to improve recyclability of problematic systems Cooperation now with HP, NexPress, Océ, Ricoh, Xeikon, Xerox, Lexmark Recyclability is now accepted as an important product characteristic (partners in the paper chain) Contact to ink suppliers? Task Force in cooperation with CTP (Grenoble) European Round Table European Round Table 20 participants yet first meeting in Munich, Jan 2006 definition of recyclable uniform test pattern survey deinkability next meeting: Novt 8, 2007

24 European Round Table unique test pattern public domain b/w and color A4 and letter available on INGEDE s website European Round Table Survey Limit 2, MM MY TK ZP TN ZS ZT ZR MP PB MN TL ZU MW FS MQ ZV MO TM MR ZA ZW ZB MZ PA (on hold) ZX MB MC MS ZY ZZ MX MT MU 0 Specks [mm²/m²] Yield [%]

25 European Round Table Survey ZP before and after deinking European Round Table Survey ZS before and after deinking

26 European Round Table Survey ZU before and after deinking Recyclability of Newspapers Offset/Flexo Newspapers - Luminosity Y after Deinking A B CH CZ D F GB S SF Ink Jet ,2 50, Different Newspapers PMV / 11. March 2007 F Luminosity

27 Recyclability of Newspapers Offset/Flexo Newspapers - Filtrate darkening Y A B CH CZ D F GB S SF F Ink Jet 10 7,2 7, Different Newspapers PMV / 11. March 2007 Filtrate Darkening Y Recyclability of Newspapers Offset/Flexo Newspapers - Value a* of deinked pulp A B CH CZ D F GB S SF Ink Jet: <-3, ,3 47 Different Newspapers -1,3 PMV / 11. March 2007 a*-value

28 What did we learn? A lot about toners and fusion technology fusion temperatures (!!!) toner formulations printing conditions deinking conditions Little about ink jet inks small pigments create big problems no cooperation with inkjet manufacturers Legal implications example European packaging waste recovery targets: UK must recover 60% of all packaging waste by end of 2008, as well as meeting a number of other targets. UK targets have been set by Defra. EU Directive is a "producer responsibility" measure, so it is up to packaging producers to meet the costs of achieving these targets. The UK's Producer Responsibility regulations affect any company involved in the packaging supply chain that is larger than 2 million turnover, or which handles more than 50 tonnes of packaging each year.

29 Legal implications German law: A product that endangers an existing recycling cycle has to be labelled. NOT RECYCLABLE Trash after reading Conclusions Difficult to change the process too many and too different challenges, costs! Change collection? Communication? Label? Change inks?

30 Thank you!