AGFA GRAPHICS. Alluring? Closed loop recycling for lithographic aluminium? Peter Verschave IFEST 2012

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Brittany Anis Logan
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1 Alluring? AGFA GRAPHICS Closed loop recycling for lithographic aluminium? Peter Verschave IFEST Februari 2012

2 Agfa Graphics in the Agfa-Gevaert Group GLOBAL TURNOVER billion euro 53% AGFA GRAPHICS 40% AGFA HEALTHCARE 7% AGFA MATERIALS Agfa Graphics 2/28/2012 2

3 Our Customers Commercial printers Packaging printers Newspapers services Sign & display printers software complete solutions consumables hardware Agfa Graphics 2/28/2012 3

4 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

5 Our position in the printing industry Creation Pre press Printing and finishing Text Images Editorial Process Page Layout Preflight Proofing Plate-making Printing Finishing Advertising 5 Agfa Graphics 2/28/2012 5

6 Offset printing Agfa Graphics 2/28/2012 6

7 Profit Planet People Ou ur World Our Products Our Customers Our Operations Agfa Graphics 2/28/2012 7

8 Our World Sustainable Development for a Sustainable Print Business Agfa Graphics 2/28/2012 8

9 Our World 2 levels to reduce our environmental footprint: How we manufacture and distribute the product The way how the product is used by our customers Agfa s performance worldwide: Water Usage -27.0% CO 2 Emissions -42.8% Energy Usage -22.4% VOC Emissions -73.3% ISO14001, OHSAS18001 & ISO50001 Worldwide SER-Programme Packaging & logistics programmes Agfa Graphics 2/28/2012 9

10 Our World 2 levels to reduce our environmental footprint: How we manufacture and distribute the product The way how the product is used by our customers Sustainable Product Development Customers performance: Water Usage CO 2 Emissions Energy Usage VOC Emissions Cost impact Ease of Use Process stability Product life cycle assessment studies Agfa Graphics 2/28/

11 100.0% 90.0% 80.0% 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% -10.0% -20.0% -30.0% LCA impact categories for 1m 2 of newspaper EoL treatment (non-recylced) EoL collection Distribution Printing Prepress Paper (printing) Ink (printing) Chemicals (printing) Climate change Ozone depletion Human toxicity Photochemical oxidant formation Particulate matter formation Terrestrial acidification Freshwater eutrophication Marine Eutrophication Terrestrial ecotoxicity Freshwater ecotoxicity Marine ecotoxicity Agricultural land occupation Urban land occupation Natural land transformation Water depletion Metal depletion Fossil depletion LCA study by Vito, commissioned by Corelio, Febelgra & Agfa Agfa Graphics 2/28/

12 LCA impact categories for 1m2 of N94VCF Agfa LCA Graphics study by Vito, commissioned 2/28/2012 by Agfa12

13 Example: climate change impact Agfa Graphics 2/28/

14 Example: climate change impact Agfa- and Prepress process steps Production of Litho aluminium base Carbon footprint (in kg CO2-eq./m² plate) Amigo Azura Column2 N92 VCF N92 Violet Column7 Energy Elite P970 Thermostar Agfa Graphics 2/28/

15 Example: climate change impact Agfa- and Prepress process steps Production of Litho aluminium base Carbon footprint (in kg CO2-eq./m² plate) Amigo Azura Column2 N92 VCF N92 Violet Column7 Energy Elite P970 Thermostar Agfa Graphics 2/28/

16 Climate change exclusive the Al production Agfa Graphics 2/28/

17 Use at the printer Agfa Graphics 2/28/

18 Example: climate change impact Agfa- and Prepress process steps Production of Litho aluminium base ca. 80% of the impact Carbon footprint (in kg CO2-eq./m² plate) Amigo Azura Column2 N92 VCF N92 Violet Column7 Energy Elite P970 Thermostar Agfa Graphics 2/28/

19 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/

20 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 Al 2 O 3 surface layer hard, porous and hygroscopic cfr. wet offset mechanism Agfa Graphics 2/28/

21 Offset printing plate AA1050 Electrograining Anodising Developed printing plate Exposed printing plate Light sensitive coating Plate Manufacturing Pre-press Production Agfa Graphics 2/28/

22 Basic principle wet offset print Hydrophilic Al 2 O 3 layer Image layer ink H 2 O H 2 O H 2 Oink H2 Oink ink H 2 O ink ink Agfa Graphics 2/28/

23 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 Al 2 O 3 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/

24 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: Agfa Graphics 2/28/

25 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: Agfa Graphics 2/28/

26 Cradle 2 Cradle litho aluminium Feasibility study Technical Business Logistics LCA impact Partners + litho aluminium supply- and scrap partners Project approved within the 3 rd programme of MIPVlaanderen Project name: Alluring? Agfa Graphics 2/28/

Current product flow Lithographic Al manufacturer / roller Al plate producer LME offset plates Primary Aluminium New Al (100%) Rolled Al Degreasing Graining, anodizing Surface treatment, coating

27 Current product flow Lithographic Al manufacturer / roller Al plate producer LME offset plates Primary Aluminium New Al (100%) Rolled Al Degreasing Graining, anodizing Surface treatment, coating Cutting and packaging Waste Al with IL-paper Other Al applications (downcycling ) Al Recycling Remelting and alloying High value Alu scrap External scrap collector Al scrap from other sources Used plates Printer Agfa Graphics 2/28/

28 Alluring? concept and project partners Agfa Graphics 2/28/

29 Alluring? Start: 1 st 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, Al 2 O 3, 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/

30 Agfa Graphics 2/28/

Sustainable Manufacturing Seminar. Designing to Sustain the Economy, Environment and Society. Sustainable Product Standards (case-study)

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