Improving. the Recyclability of Printed Products. INGEDE Seminar October 5, Hôtel Concorde St. Lazare Paris

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1 Perfectionner le recyclage des produits imprimés Improving the Recyclability of Printed Products INGEDE Seminar October 5, 2006 Hôtel Concorde St. Lazare Paris

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3 INGEDE Seminar October 5, 2006 Hôtel Concorde St. Lazare Paris

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5 Program and Contents 10:00 Déclaration Européene sur le recyclage des Papiers et Cartons The European Declaration on Paper Recycling Bernd Böcking 10:30 Présentation d'ingede Introduction to INGEDE Corinne le Ny, UPM Chapelle Darblay 11:10 Marché des Papiers récupérés en France et en Europe Recovered Paper Market in France and in Europe Jean Francois Serre, Norske Skog Golbey :00 Lunch Break 13:30 Systèmes de collectes en Suisse Collection System in Switzerland Stefan Junginger, Papierfabrik Utzenstorf 14:10 Procédés de désencrages et problèmes rencontrés Adhésifs, encres numériques et flexographiques Deinking Process and Problems Adhesives, Digital and Flexo Inks Corinne Le Ny, UPM Chapelle Darblay 14:50 Recherche et évaluation de la recyclabilité Research and Assessment of Recyclability Benjamin Fabry, CTP :30 Discussion, Conclusion Bernd Böcking Appendix Guide to an Optimum Recyclability of Recovered Paper 123 Recovered Paper is a Valuable Resource: Separate Collection is Necessary 129 (INGEDE Press Release)

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7 Participants CEPI Confederation of European Paper Industries, Belgium Consultant CTP Centre Technique du Papier CTP Centre Technique du Papier Emap France Environnement Magazine INGEDE Office, Germany Myllykoski Continental, Papierfabrik Utzenstorf, Switzerland Norske Skog Golbey Pap Argus Pap Argus Quebecor World Europe Revue du Papier Carton SICOGIF Syndicat National des Industries de la Communication Graphique et de l'imprimerie Française SICOGIF Syndicat National des Industries de la Communication Graphique et de l'imprimerie Française SPP Syndicat de la Presse Parisienne) Stora Enso Office Paris Stora Enso Office Paris Stora Enso Office Paris Stora Enso Office Paris Stora Enso Office Paris UPM Chapelle Darblay Ulrich Leberle Bernd Böcking Benjamin Fabry Sandrine Poncet-Pappini Nathalie Pétré Martine Chartier Andreas Faul Stefan Junginger Jean Francois Serre Ghislaine Blery Patricia Fortin M. David Beaufils Danièle Bouvron Philippe Queinec Chantal Richardeau Jean-Pierre Guérin Gerald Berne Laure Berranger Olivier Boizard Francois Xavier Danel Michael Dureuil Corinne le Ny (as of September 20, 2006) 7

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9 Déclaration Européene sur le recyclage des Papiers et Cartons The European Declaration on Paper Recycling Bernd Böcking 9

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11 European Declaration on Paper Recycling

12 Table of Contents Introduction European Declaration on Paper Recycling Glossary Towards a common goal of sustainability - the European Declaration on Paper Recycling Recycling has formed an increasing part of the paper manufacturing process and it is now a large industry in its own right, linking directly or indirectly to a large number of sectors in the European economy. The voluntary European Declaration of 2000 promoting paper recycling has made a positive contribution to this process. And it all brings us a step closer to the European Commission s goal of Europe as a recycling economy, supporting Europe s sustainable development and long-term, robust growth and employment. Continuing this successful initiative, a new Declaration covering more European countries, more European organisations and with greater ambition was launched in September In practice, this translates to groundbreaking research and development, significant investments in new capacities, a focus on quality and responsible sourcing, and on raising public awareness. Together these sectors will develop a sustainable path in paper recycling, making it possible to reach the new target of a 66% recycling rate by

13 European Declaration on Paper Recycling Paper is already one of the best managed raw materials, boasting high recovery and recycling rates. Even so, the industry strives to do better OBJECTIVE The European Declaration on Paper Recycling sets out measures aimed at optimising the management of recovered paper throughout the value chain from paper and board manufacturing, converting and printing through to the collection, sorting and transportation of used paper and board products. Paper is already one of the best managed raw materials, boasting high recovery and recycling rates. Even so, the industry strives to do better. Consequently, all of the Signatories and Supporters of this Declaration aim to ensure that correct systems are in place to encourage paper recycling, building on the very positive progress made by the first European Declaration on Paper Recovery ( ; see Signatories and Supporters of the Declaration accept voluntarily to undertake a number of complementary actions contributing to this target wherever technically possible and economically reasonable. Priority is given to the prevention of waste including its environmental impact during the manufacture of paper and board products, through to collection and processing of used products and the recycling of recovered paper, thus reducing the quantity of used paper-based products destined for final disposal. Close attention is also being paid to improving the recyclability of paper and board products and - where applicable - the deinkability of paper and board products. Combining these goals with continuing efforts to improve the quality of recovered paper will undoubtedly help to reinforce its character as a valuable secondary raw material for the paper industry. The industry aims to make optimum use of the characteristics inherent in different grades of recovered paper, matching their properties with the requirements of the end product. At the same time, the drive towards high levels of recyclability should also take into account the efforts expected from specific industry sectors to meet the requirements of environmental legislation SCOPE - COVERAGE The Declaration shall cover all paper and board products. It shall apply without prejudice to relevant European Community legislation and national legislation, which currently covers a number of issues related to the production, utilisation, recycling and recovery of paper and board. The Declaration covers the 25 Member States of the European Union as well as Bulgaria, Norway, Romania and Switzerland. All commitments are fixed at a European level as defined by this Declaration and the integration and cooperation between all the Signatories and Supporters should guarantee that the commitments are met at European level. Thus, none of the commitments are intended to apply to single countries or individual organisations or individual companies. The Declaration attempts to provide complementary measures designed to ensure an environmentally sustainable paper value chain and good communication between the relevant stakeholders. The Declaration does not attempt to harmonise national systems or prejudice producer responsibility agreements/legislation at national level

14 European Declaration on Paper Recycling 1.3. PARTIES TO THE DECLARATION 1. The following European associations are Signatories of the European Declaration on Paper Recycling: CEPI Confederation of European Paper Industries CITPA International Confederation of Paper and Board Converters in Europe ERPA European Recovered Paper Association ETS European Tissue Symposium INGEDE International Association of the Deinking Industry INTERGRAF International Confederation for Printing and Allied Industries 2. The following European associations are Supporters of the European Declaration on Paper Recycling: ENPA European Newspaper Publishers Association EuPIA European Printing Ink Association, a sector of CEPE FAEP European Federation of Magazine Publishers FEICA Association of European Adhesives Manufacturers FINAT Worldwide Association for Self-Adhesive Labels and Related Products RadTech Europe European Association for the promotion of UV and EB curing 1.4. ACCESSION OF OTHER PARTIES The Declaration is open to other European associations, whose members are involved directly or indirectly in the paper value chain DEFINITION OF TERMS To provide a broad and common understanding of this Declaration in Europe, an agreed terminology is necessary. This is partly drawn from definitions that already exist in European Community legislation and partly based upon terms used in industrial and commercial activities within the European paper value chain. These definitions are listed in the Glossary PREVENTION OF WASTE All the Signatories shall endeavour to reduce the generation and environmental impact of waste during manufacturing, converting/printing, collecting, sorting and recycling processes to ensure the optimal and environmentally sound recycling of used paper and board products COLLECTION 1. Recovered Paper Collectors and Merchants shall endeavour to improve the collection of used paper and board, as far as possible and in cooperation with other concerned Signatories and Supporters, in such a way as to achieve a high level of separate collection that will subsequently allow for a high rate of material recycling of recovered paper (see ). 2. All the Signatories shall continue to offer recovered paper collectors, merchants or interested parties advice on setting up collection systems in order to achieve an optimal combination of cost, quantity and quality. A system has been established to allow an exchange of information on national initiatives and experiences at European level. 3. As a complement to the EN 643 European List of Standard Grades of Recovered Paper and Board, all the Signatories concerned shall determine and promote specific Guidelines on e.g. recovered paper quality control for used paper and board products collected from various sources (i.e. household or similar, industry and trade) RECYCLING 1. The European Paper & Board Manufacturing Industry as a whole with the support of other concerned Signatories of the Declaration and subject to the development of the international market shall take measures to ensure that by the year % of the paper and board products consumed in Europe will be recycled. A margin of +/- 1.5% points 1 has to be taken into consideration to adjust for the fluctuations of the international paper market and the target recycling rate includes net recovered paper exports to countries outside Europe (see 1.2). 2. Signatories and Supporters reaffirm their support for the concept of good recyclability for paper and board products. Furthermore, the Signatories and Supporters agree to publish guidelines and methods of assessment to promote good recyclability practices and to update the guidelines as appropriate. 3. The European Newspaper and Magazine Publishers and the European Printing Industries undertake to establish and promote compliance with new or existing recommendations on improving the deinkability and recyclability of the paper and board used for printing and/or converting processes % %

15 European Declaration on Paper Recycling 4. The European Producers of Paper and Board Packaging shall ensure that the design of packaging includes consideration of aspects significant for the recycling of the materials from which it is produced in line with relevant European standards. 5. The European Printing Ink Manufacturers and the European Adhesives Manufacturers promote the development and availability of printing inks and glues that do not hamper the recycling and deinking processes and the quality of recycled products. 6. The Manufacturers and Converters of Self-Adhesive Materials for the Label Industry undertake to promote the development and use of recycling solutions for siliconised paper liners. 7. The Manufacturers of UV and EB Curable Raw Materials and Processes undertake to develop and offer systems for the printing and coating industries that do not hamper the recycling and deinking processes and the quality of recycled products. 8. All the Signatories and Supporters covered under Sections to commit to ongoing discussion and collaboration on matters of common concern (printability, recyclability, deinkability) with regard to used paper and board and paper and board products. The participants shall strive for a mutual understanding concerning justified sectoral interests and common obligations RESEARCH AND DEVELOPMENT To further improve the recyclability and deinkability of paper and board products, all the Signatories and Supporters shall encourage and promote research and development in areas such as: paper and board manufacturing processes, along with raw and auxiliary materials and converting/printing technology recovered paper processing technology management and recycling of residues as a means of increasing the eco-efficiency of recycling and reducing environmental impacts. Information on these areas shall be made adequately available EDUCATION AND INFORMATION All the Signatories and Supporters concerned shall take action to provide information that will help educate and raise the awareness of consumers and public bodies about their respective roles in completing the paper loop. A common communication strategy will be considered and coordinated by the European Recovered Paper Council EUROPEAN RECOVERED PAPER COUNCIL (ERPC) 1. The European Recovered Paper Council was initiated by the Signatories. The constituting parties are: Signatories Supporters Observers Details of the individual roles of these parties are stated in the By-laws which form an integral part of this Declaration. 2. The European Recovered Paper Council has the following tasks: to coordinate the commitments of all the Signatories and Supporters to take steps to improve the quality of the information available to discuss all relevant matters regarding the successful operation of the European Declaration to coordinate public information on the achievements of the European Declaration to produce annual reports 3. All the Signatories and Supporters should collect the relevant information required on an annual basis. The ERPC will compile and produce a joint report from this data. The report will include measures taken, progress achieved (with specific quantification when applicable) and verifiable information on the fulfilment of the commitments. 4. Representatives of the EU institutions will be invited to attend the ERPC gatherings as Observers. 3. DURATION AND REVISION The Declaration will be valid for an unlimited period. A first review of this Declaration was based on the quantified recycling commitment for the year A second review will be based on the outcome of a quantified recycling commitment for the year

16 Signatories and Supporters of the European Declaration on Paper Recycling Signatories Teresa Presas Managing Director CEPI Silvio Sanguinazzi President CITPA Maarten Kleiweg de Zwaan President ERPA Phil Mogel External Relations Manager ETS Ulrich Höke Chairman INGEDE Beatrice Klose Secretary General INTERGRAF Supporters Valtteri Niiranen Director ENPA Felipe Mellado Chairman EuPIA David Hanger President FAEP Ansgar van Halteren Secretary General FEICA Jules Lejeune Managing Director FINAT Philippe Goethals President RadTech Europe (RTE) 16 September

17 Glossary TERMINOLOGY Collection (of paper and board) Consumer Consumption (apparent) Converter Deinkability Distribution (of paper & board) Final disposal Manufacturer Packer/filler Paper Paper product Paper value chain Printer Publisher Recovered paper (RP) RP collector RP merchant RP trader Recyclability Recycling Recycling rate Waste DEFINITION Separate collection of paper and paper products from industrial and commercial outlets, from households and offices for Recovery. (Collection includes transport to the sorting/processing or recycling plant/paper mill). Industrial, commercial or private end-user. Internal deliveries into the defined countries (see 1.2) plus imports from countries outside this coverage. Processor of paper or board as a raw material (such as packaging, printing). Removal of ink and/or toner from a printed product to a high extent by means of a deinking process. This shall restore as good as possible the optical properties of the unprinted product. Wholesale and retail trade of paper and board material and products ensuring the link between the producer/converter or importer and the final consumer. Definitive deposit of waste to landfill or incineration without energy recovery. Producer of paper and/or board. User of packaging material to put a product into marketable units. Term used to cover all grades of paper and board. General term used to cover all paper and board-based converted products. All parties, linked directly or indirectly, from paper and board manufacturing to the collector/merchant of used paper and board products. Manufacturer of printed products using paper or board as printing surface ( Converter). One who publishes (owns and brings to the market) products which are printed on paper. Used paper and board separately collected and in general processed according to the European Standard List of Recovered Paper and Board Grades. One who separately collects used paper and board; he may also have processing (sorting, handling) transport or trade activities. One who primarily buys, processes and sells RP; he may be actively involved in its collection. One who buys and sells RP without any operational collection or processing activity. Design, manufacturing and converting of paper based products in such a way as to enable a high quality recycling of fibres and other materials in a manufacturing process in compliance - where appropriate - with current standards in the Community. Reprocessing of RP in a production process into new paper and board. The ratio between RP utilised for Recycling including RP net trade, and paper and board consumption. Any substance or object which holder discards or intends or is required to discard. Note: Paper and board products, once they have been collected and processed for further recycling, become a valuable secondary raw material and should no longer be considered as waste, according to the paper industry and the RP collectors, merchants and traders

18 Paper kindly supplied by HURUM Papir AS Norgraph recy white paper 250g made of 80% recovered beverage cartons Signatories Supporters European Recovered Paper Council c/o CEPI aisbl Avenue Louise 250 Box 80 B Brussels Tel Fax j.ringman@cepi.org 18

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21 Présentation d'ingede Introduction to INGEDE Corinne le Ny 21

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23 INGEDE Seminar 5 October 2006 in Paris Introduction to INGEDE Corinne le Ny R&D manager UPM Kymmene Chapelle Darblay International Association of the Deinking Industry Who is INGEDE? Leading European paper manufacturers with deinking plants founded the International Association of the Deinking Industry, a non profit organisation, in Currently 40 paper mills are members of INGEDE: 23

24 40 INGEDE Members Cartiere Burgo S.p.A. Mantova; Marzabotto Dalum Papier A/S Odense Holmen Paper AB Braviken; Madrid LEIPA Georg Leinfelder GmbH Schwedt Lenzing AG Lenzing Myllykoski Continental Group Lang Papier Ettringen; MD Papier Plattling; Papierfabrik Utzenstorf; Rhein Papier GmbH Metsä Tissue Kreuzau; Raubach M-Real New Thames Ltd. Kemsley Norske Skog Group Bruck; Golbey; Parenco; Skogn; Steti Packages Ltd. Lahore Papierfabrik Hainsberg GmbH Hainsberg Papierfabrik Palm GmbH & Co KG Aalen; Eltmann Perlen Papier AG Perlen SCA Graphic Laakirchen AG Laakirchen SCA Hygiene Consumer Products Mannheim SCA Hygiene Products Away from Home Mainz-Kostheim Steinbeis Temming Papier GmbH Glückstadt Stora Enso Group Hylte; Langerbrugge; Maxau; Eilenburg Keräyskuitu OY Sunila UPM-Kymmene Group Augsburg; Chapelle Darblay; Kaipola; Schongau; Schwedt; Shotton; Steyrermühl Recovered paper usage of INGEDE members x tons (est.)

25 Objectives of INGEDE Support voluntary commitments of the paper chain for challenging recycling targets Establish recyclability as an important criterion for the design of printed products Finance common research and communicate the results What does INGEDE do? Research Projects Communication with members of the paper chain and the public Test Methods and Procedures Representation in Technical Committees Exchange of Experience 25

26 Fields of INGEDE Research Share of Funds 21% 10% 17% 11% 5% 36% Recovered Paper Recyclability Basic Research Process Environmental Methods Communication with the paper chain Waste Management Companies Recycled Paper Mills Consumer Publishing / Printing Converting Ink & Material Suppliers Adhesives 26

27 Work for Improving the Recyclability of Printed Products The European version of the Guide to an Optimum Recyclability of Printed Graphic Paper was approved by several European Associations in March 2002 INGEDE is a signatory of the European Declaration on Paper Recycling in its new version of 2006 Orientation values for recyclability are adopted on German level and will be discussed in ERPC Challenges for Recyclability Customers demand brighter paper This would require better input, but: Quality of recovered paper gets worse New digital print processes and flexo newspapers challenge both the recovering strategies and the deinking process More ink and more colour on less paper 27

28 Printing and Deinking Current and Future Challenges Use of recovered paper in higher quality papers/ in higher percentages Need for higher recovered paper qualities/fractions Prevention of prints with insufficient deinkability flexo prints, UV prints, some digital prints etc. Prevention of not removable adhesive applications 28

29 INGEDE International Association of the Deinking Industry INGEDE Office Gerokstr Bietigheim-Bissingen Germany Phone Fax Mail Public Relations Oetztaler Str. 5 B München Germany Phone Fax Mail info@ingede.org 29

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31 Marché des Papiers récupérés en France et en Europe Recovered Paper Market in France and in Europe Jean Francois Serre 31

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33 European Recovered Paper Market Paris, 5 October 2006 Jean-François Serre, Norske Skog Europe Mill Recovered Paper Supply Director Global development of Collection Rate vs Net Trade % Western Europe 60 % Asia North America 50 % Oceania 40 % Latin America Eastern Europe 30 % Africa 20 % t Source : CEPI 33

34 Major Global Trade Flows of Recovered Paper China Other Asia China 3 Other Asia 1 2, Total 35 million tons Source: Jaakko Poyry Consulting Recovered Paper consumption and recovery in CEPI countries Million Tonnes Evolution of Paper Consumption and Recovery in CEPI Countries Recycling in Paper Mills Non Recoverable* --- consumption of paper and board Recovered Paper Net Trade Other Recycling / Recovery or Final Disposal Source : CEPI 34

35 Recovered Paper Utilisation and Recycling Rate in CEPI Countries Recovered Paper Utilisation and Recycling Rate in CEPI Countries Million Tonnes percentage Recovered Paper Utilisation Recycling Rate Source : CEPI 32 Recovered Paper Utilisation by sector in CEPI Countries in Case materials Utilisation Rate (%) Newsprint Carton Boards Wrappings, other pack.paper Household & sanitary Others Other graphic grades Share of Total Paper & Board Production (%) Mixed Grades Newspapers and Magazines Corrugated and Kraft High Grades 35

36 Recovered Paper Collection rate, utilisation rate and utilisation in CEPI countries in 2005 Collection Rate (%) DE 80 SE CH NL FI AT 70 UK NO FR 60 BE 50 ES 40 PT SK HU CZ IT 30 PL Utilisation Rate (%) For instance: United Kingdom has a collection rate of 56,9%, a utilisation rate of 74,1% and consumed 4.6 million tonnes of recovered paper in 2004 (bubble size is proportional to Recovered Paper utilisation) Recovered Paper Trade evolution Recovered Paper Trade Balance by Country ('000 Tonnes) UNITED KINGDOM BELGIUM GERMANY FRANCE DENMARK IRELAND SWITZERLAND ITALY PORTUGAL POLAND FINLAND NORWAY CZECH REPUBLIC NETHERLANDS HUNGARY SLOVAK REPUBLIC SPAIN SWEDEN AUSTRIA Source : CEPI -1,500-1, ,000 1,500 2,000 2,500 3,000 3,500 36

37 Current and Future challenges Even with European steady growth of net trade, Paper Industry is facing several challenges. 1. RP availability 2. RP quality 3. Energy 4. Transport European RP Availabilty Analysis RP Exporters Surplus Shrinking DRYING European RP Availabilty Analysis UK RP Exporters Surplus Growing RESERVOIR Net trade evolution D F I NL SP DANGER RELAXING RP I t RP Importers RP Importers RP I t Net trade 2010 Shrinking Deficit Growing Deficit 37

38 RP quality Quality is decreasing worldwide: Co-mingled collection Sorting equipment not optimal Competition for securing RP sources Paper Industry should: promote CEPI guidelines: Responsible sourcing and RP identification (comingled collection must be marked on delivery document. Cf. EN 643 norm). RP quality control and entry inspection. Support new technology development for better sorting. RP quality trend [%] EONP AONP target KONP EONP : European ONP. AONP : American ONP. KONP : Korean ONP Source : Norske Skog Pan Asia 38

39 Energy Energy price put pressure on alternative RP usage as biofuel. This could put in danger RP supply in the Paper Industry. Paper Industry should promote the 3Rs hierarchy: Reduce Reuse Recycle (as secondary raw material) CEPI and Paper Industries should put pressure on countries which don t comply with EU regulation for collection rate target. Transport Small transport companies disappear. Trucks shortage for long distances Safety issues with foreign trucks drivers who can t speak and understand home country language or English. Paper Industry should : Optimise supply area around the mill. Develop alternative transport to road. Optimise transport with finish goods distribution 39

40 Conclusion RP bad quality, transport, energy, RP availability are pushing Paper Industry costs up. Paper Industry should improve business relationships with their suppliers to reduce the total cost to the mill through: Better RP quality Better logistic optimisation Better RP availability 40

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43 Systèmes de collectes en Suisse Collection System in Switzerland Stefan Junginger 43

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45 Collecte séparée du carton et du vieux papier l expérience suisse Stéfan Junginger (Rhein Papier) Ingede Paris 5 octobre Table des matières 1. Vue d ensemble aspects quantitatifs 1.1. Sources flux de papier & de carton en Suisse 1.2. Collecte de vieux papier & consommation 1.3. Comment augmenter l utilisation du vieux papier en Suisse? 2. Aspects qualitatifs du recyclage du vieux papier - Recyclabilité 3. Comment le vieux papier est collecté en Suisse? 3.1. La législation suisse en matière d environnement 3.2. Systèmes de collecte 3.3. Logistiques & contrats 4. Expérience d une fabrique de papier suisse Ingede Paris 5 octobre

46 1. Vue d ensemble Aspects quantitatifs 1.1. Sources flux de papier & de carton en Suisse (étude du flux de fibres) Ingede Paris 5 octobre Flux de recyclage du papier & du carton 2003 (estimations; source: Stofffluss-Studie STAR) flux retour avant consommation (déchet avant consommation) Retour de vieux papier et de carton après consommation Usine d incinération et épuration des eaux usées Collecte auprès des industries et des commerces Collecte auprès des ménages t/a % Ingede Paris 5 octobre

47 Origine du vieux papier collecté en Suisse en 2003 (estimation) Collecte Vieux papier issu production de papier, carton Vieux papier issu imprimerie, converteur Vieux papier issu de cartons, emballages collecte urbaines % 18% 20% 49% surtout du papier surtout emballage 460'000 papier 10'000 cartons issus des ménages 80'000 cartons issus de petites entreprises Utilisation collecte industrie, commerce % minus Export 318 plus Import 249 Ingede Paris 5 octobre Vue d ensemble Aspects quantitatifs 1.2. Collecte de vieux papier & comsommation Ingede Paris 5 octobre

48 Vieux papier taux d utilisation et taux de collecte dans les pays CEPI (2003) 100% 90% DE Taux de collecte % 80% 70% 60% 50% 40% 30% FI SE NO PT SK BE PL CZ AT CH IT FR HU NL UK ES 20% 10% (taille des bulles en fonction de la consommation de papier) 0% 0% 20% 40% 60% 80% 100% Taux d utilisation % Ingede Paris 5 octobre Schéma du papier recyclé en Suisse chiffres clés pour 2003 production de papier&carton t consommation vieux papier t Taux d utilisation 58.3 % - Export t + Import t Taux de recyclage 65.5 % - Export t + Import t Consommation de papier&carton t récupération de vieux papier t Taux de collecte 69.9 % Ingede Paris 5 octobre

49 Consommation et collecte de papier et carton en Suisse en 2003 Population Population par km 2 Consommation de papier et de carton par tête Collecte de vieux papier Collecte de vieux papier par tête habitants kg/a tonnes 153 kg (par ménage =75 kg) Ingede Paris 5 octobre Vue d ensemble Aspects quantitatifs 1.3. Comment augmenter l utilisation du vieux papier en Suisse? Ingede Paris 5 octobre

50 Pourquoi augmenter le collecte et l utilisation? Pour des raisons économiques Pour des raisons écologiques Pour des raisons techniques Ingede Paris 5 octobre Taux d utilisation pour les papiers et carton en Suisse 2003 Taux d utilisation, % Moyenne carton: 74.2 % Moyenne totale: % 40 News 30 Moyenne des journaux & autres 20 imprimés: 28.9 % 10 Autres papiers imprimés en % de production de papier & carton Ingede Paris 5 octobre Boîtes Cartonages pliables ménage & sanitaire Autres cartons 50

51 Le potentiel en Suisse source: BUWAL study on composition of municipal waste 2001/2002 (Schriftenreihe Nr. 356) Ingede Paris 5 octobre résumé de l étude sur la composition des déchets urbains Le total des déchets urbains des ménages pour l incinération en 2002 était de tonnes dont 16% de papier ( tonnes) dont 4% de carton ( tonnes) Un potential réaliste de tonnes supplémentaires de vieux papier et de carton issues des communes Un faible tonnage supplémentaire de vieux papier issu des industries et des sociétés de service (aucune étude disponible) Un taux de collecte normal de 69,95% passerait à 74% Ingede Paris 5 octobre

52 Mesures nécessaires Amélioration de la qualité de la collecte Rendement de collecte accrû grâce à une collecte plus efficace Conception de produits adaptés, d une plus grande recyclabilité Ingede Paris 5 octobre Aspects qualitatifs du vieux papier - Recyclabilité Ingede Paris 5 octobre

53 Usage du processus de désencrage pour les papiers graphiques imprimés Conditions : performance des usines de désencrage ne peut plus être réduite la quantité de papiers graphiques imprimés recyclés utilisée dans les nouvelles impressions ne peut plus être augmentée le tri des déchets de papiers graphiques doit être accru il faut prêter plus d attention à la bonne recyclabilité des produits graphiques imprimés. Ingede Paris 5 octobre Conditions obligatoires pour préserver les fibres des déchets de papiers graphiques dans le but d une réutilisation sans problème* des papiers, des encres d impression, des rubans adhésifs et autres matériaux auxiliaires, d une bonne recyclabilité, doivent continuer à être développés des encres d impressions et des systèmes de reliure adhésifs qui supportent une bonne recyclabilité doivent être développés et être utilisés en priorité de nouvelles technologies d impressions ne doivent pas être développées en excluant la finalité d une bonne recyclabilité dans la spécification de leurs produits (les processus d impressions digitales actuels sont un mauvais exemple) plus sur Ingede Paris 5 octobre

54 Cibles de la recyclabilité: Test de désencragilité Processus d impression Coldset Offset (Newsprint) Heatset Offset Heatset Offset Rotogravure Qualité de papier non glacée non glacée glacée non glacée glacée vierge 1) Paramètre optique DIP Y Y IE % a* Y 63,5 54 > 55 63,5 ( 53) ( 63) ( 66) 57 ( 54) 75 ( 74) 2,5 à 1 ( -3,5 à 1,5) Speck area mm 2 /m 2 sousdéveloppement d une procédure de calibration 1) Standard ou luminosité requise de niveaux de papier standard contenant du bois International Association of the Deinking Industry Ingede Paris 5 octobre Matériaux d emballage dans le papier graphique recyclé Dispersion avec: 4% de Peroxyde 2.5% de Peroxyde (estimé) 1% de Peroxyde 0.5% de Peroxyde (estimé) 0% de Peroxyde (Recette chimique numéro 1 à 4) Matériaux d emballage % Association internationale des industries de désencrage Ingede Paris 5 octobre

55 exemple de la méthode INGEDE INGEDE Méthode 7: contrôle d admission du vieux papier grade 1.11 (pas en balles) Association internationale des industries de désencrage Ingede Paris 5 octobre Résultats: contrôle d admission matériaux impropres 12,0 10,0 8,0 moyenne la plus défavorable moyenne % 6,0 4,0 2,0 0, Association internationale des industries de désencrage Ingede Paris 5 octobre

56 Contrôle d admission refus 7,0% 6,0% 5,0% % 4,0% 3,0% 2,0% 1,0% Quote-part 0,0% Association internationale des industries de désencrage Ingede Paris 5 octobre Comment le vieux papier est collecté en Suisse? 3.1 Droit de l environnement suisse Ingede Paris 5 octobre

57 Les règles de priorité (source: Loi sur la protection de l environnement (LPE) et Ordonnance sur le traitement des déchets (OTD) Prévention des déchets (LPE Art. 30) Recyclage avant élimination Interdiction de mise en décharge de matériau incinérable (LPE Art. 30c et OTD Art. 32). Ingede Paris 5 octobre Statut légal du vieux papier (source: Loi sur la protection de l environnement (LPE) et Ordonnance sur le traitement des déchets (OTD) LPE Art 30c: les déchets doivent être traités de façon à contenir le moins possible de carbone organique et à être aussi peu solubles dans l eau que possible. L incinération n est autorisée que dans des installations LPE Art. 30d: le Conseil fédéral peut prescrire le recyclage de matériau spécifique TVA Art. 32: les déchets suivants ne sont pas autorisés dans les décharges: déchets liquides, déchets explosifs, déchets infectieux, déchets urbains, boues d épuration, déchets de chantier et autres déchets combustibles Ingede Paris 5 octobre

58 Financer les différentes collectes Manière d enlever les ordures Collecte séparée du verre, du papier, etc. (matériau recyclable) Déchets urbains (incinération) décharge (restreinte) Financement a) Recouvrement anticipé b) Taxes de base a) Vous payez à hauteur de ce que vous jetez* b) Taxes de base / taxes Vous payez à hauteur de ce que vous jetez* * Au poids ou à l unité Ingede Paris 5 octobre Comment le vieux papier est collecté en Suisse? 3.2. Systèmes de collecte Ingede Paris 5 octobre

59 Collecte mixte et séparée du papier et du carton - Collecte le long du trottoir Collecte séparée du papier collecte le long du trottoir (1ère image) Collecte séparée du carton collecte le long du trottoir (2ème image) Collecte mixte de papier & carton collecte le long du trottoir Ingede Paris 5 octobre Autres systèmes de collecte du papier et du carton Système de dépôt (aire de dépôt) papier séparé, carton séparé (1ère image) Points de collecte spéciaux des éditeurs et système dans les transports publics (2ème + 3ème image) Ingede Paris 5 octobre

60 exemples de dépot de papier le long du trottoir autorisé et non autorisé Ingede Paris 5 octobre exemples de transports conteneurs de 28 m 3 (10-18 tonnes) camions-bennes (7-11 tonnes) camions à chariot (de 90 m 3, tonnes) wagon E508/EAOS (15-20/30-35 tonnes) conteneurs ferroviaires ACTS (30-37 tonnes) Ingede Paris 5 octobre

61 exemples de calendriers de collecte population fréquence type de collecte volumes t/a Zürich papier: 2x / sem. carton: 12x / an le long du trottoir le long du trottoir papier: carton: St. Gallen papier: 2x / sem. carton: 6x / an le long du trottoir le long du trottoir papier: carton: Koppigen papier: 6 mois carton: 3 mois le long du trottoir aire de recyclage papier: 150 carton: 15 Bülach papier: chaque mois carton: 2x/sem.(!) le long du trottoir le long du trottoir papier: carton: Ingede Paris 5 octobre Coûts moyens de collectes en Suisse (2003) Bases: Communes pratiquant la collecte séparée du papier et du carton (130 sur 219) Euros / tonnes Coût de collecte moyen (arithmétique) Coût de collecte moyen au poids Coût de collecte médian Coût de collecte minimal Coût de collecte maximal Source: Union des Villes Suisses (UVS) Ingede Paris 5 octobre

62 3. Comment le vieux papier est collecté en Suisse? 3.3. Logistiques & contrats Ingede Paris 5 octobre Comparaison des coûts des chaînes de procédures Contrats directs Contrats traditionnels Municipalité Collecte Municipalité Collecte Transport Transport Traitement déchargement Négociant Manutention déchargement tri presse chargement marge Transport Fabrique tri? (souvent sans) Fabrique Traitement déchargement Ingede Paris 5 octobre

63 Prévalence de contrats directs Ingede Paris 5 octobre Schéma du papier recyclé en Suisse pour Collecte de vieux papier t Collectes urbaines t Contrats directs papier&carton avec les fabriques t = 52 % 1117 communes Contrat négociantsn t = 47 % 1807 communes source : ZPK Ingede Paris 5 octobre

64 Buts des contrats directs 1. Augmentation qualitative des collectes 2. Augmentation de l efficacité de la collecte des communes 3. Couverture au-moins des coûts de collecte 4. Long terme & garantie d une reprise en continu 5. Optimisation de la logistique de la source à la destination finale Ingede Paris 5 octobre Valeur ajoutée? triage (pressage des rejets compris) /t Mise en balles /t stockage (en vrac) /t Total des coûts de manutention /t plus transport Ingede Paris 5 octobre

65 4. Expérience d une fabrique de papier suisse Ingede Paris 5 octobre Structure de l offre de Utzenstorf Paper* en 2003 en milliers de tonnes 122 communes (840) 40 imprimeries (60) 28 kiosks 35 négociants Total: 230 tonnes entrée & déchargement 5 industries & petites entreprises triage & pressage +) stockage & dispatche 210 en milliers de tonnes Usine de recyclage Utzenstorf 20 autres utilisations ou ventes sur le marché Total: 230 tonnes * Utzenstorf Paper fait partie de MD Lang Paper Group +) seulement si nécessaire Ingede Paris 5 octobre

66 Inspection d entrée Classification de la collecte des mènages 4 niveaux Contenance en carton et en matériau impropre < 2 % > 2 % % carton % carton 5 % déchets % à Utzenstorf % 11 % 2 % 3 % Ingede Paris 5 octobre Le procédé doit être capable de traiter les ficelles Ingede Paris 5 octobre

67 résumé La qualité des livraisons directes est légèrement inférieure à contient < 1.5 % de carton Les livraisons directes des ménages contiennent < 2 % de carton Pour couvrir les variations saisonnières des communes, vous avez besoin de stocks élevés Les ficelles peuvent poser des problèmes. Ingede Paris 5 octobre Messages Des coûts élevés (schémas vous payez autant que vous jetez) pour les déchets urbains (débris) sont une incitation à accroître la collecte séparée de papier et de carton pour le recyclage La collecte séparée du papier et de carton baissent les coûts et augmentent la qualité de la collecte Les contrats directs nous redonnent le contrôle de la source et réduisent les coûts prédicat: des stocks élevés donnent plus de flexibilité pour gérer le flux d entrée du vieux papier. Ingede Paris 5 octobre

68 Je vous remercie de votre attention! Ingede Paris 5 octobre

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71 Procédés de désencrages et problèmes rencontrés Adhésifs, encres numériques et flexographiques Deinking Process and Problems Adhesives, Digital and Flexo Inks Corinne le Ny 71

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73 Procédé de désencrage et problèmes rencontrés Adhésifs, encres numériques et flexographiques Corinne Le Ny, UPM Chapelle Darblay Séminaire INGEDE "Perfectionner le recyclage des produits imprimés" Hôtel Concorde St Lazare, Paris Deinking in Chapelle Darblay Experience with deinking since % recycled fibres on PM3 and PM6 since deinking lines. consumption of recovered papers = t/year PM3 (1934) t/y of Color, Brite and News 1050 m/min, 5.22 m width PM6 (1987) t/y of News 1420 m/min, 8.46 m width UPM 2 73

74 Our raw materials Recovered paper collection 42 % graphic paper collection 7 % paper and board collection 51 % mixed dry recyclables Annual consumption : t Recovered paper composition 70 % old magazines + 22 % old newsprint + 5 % office papers + < 3 % unwanted materials (metal, plastic, wood, water strength papers, brown board ) UPM 3 Our raw materials inhabitants Partnership Chapelle Darblay since 1985 communication collectivity 5/6 years contract guarantee of collection + guaranteed price 450 contracts with the local communities High potential within a radius of 400 km around the mill including 30 million inhabitants service guarantee partners tri quality Chapelle Darblay UPM 4 74

75 Deinking in the old time. UPM 5 Deinking today Pulping stage: batch pulper UPM 6 75

76 or Drum UPM 7 Cleaning Light Fibres Feed Heavy Contaminants UPM 8 76

77 Screening Principle of screening Screen plate or basket stickies fibers Removal of stickies and shives -PSA, Hotmelts - glass, porcelain UPM 9 Flotation UPM 10 77

78 Ink removal at flotation Ink Precipitated Calcium Soap Air Bubble Free ink: can be removed if adequate size Attached ink: cannot be removed without fibre losses FIBRE SURFACE HIGH INK DETACHMENT, LOW INK REDEPOSITION, ADEQUATE INK PARTICLE SIZE DISTRIBUTION ARE KEY PARAMETERS FOR GOOD INK REMOVAL UPM 11 Flotation efficiency versus ink particles size distribution UPM 12 78

79 Thickening UPM 13 Dispersing UPM 14 79

80 Deinking chemistry Caustic soda increase ph swell fibres and release ink Hydrogen peroxide bleach Sodium silicate stabilise peroxide support ink agglomeration increase ph Collectors collect ink form hydrophobic surface UPM 15 Papermaking challenge Recovered papers = newsprint and magazines + limited share of office papers NO Stickies Wet Paper OUR CHALLENGE: DEINKING AND REMOVAL OF UNWANTED MATERIALS (ADHESIVES APPLICATIONS) Cardboard Flexo CDs/Cassettes Lorry Debris Dead Cats/Dogs Wood,metal,glass UPM 16 80

81 What are stickies? UPM 17 What are stickies? Adhesives = main source of stickies in recovered papers up to 1% of adhesive in recovered paper furnishes. origin: binding catalogues, magazines, books, envelopes and labels. Problems associated with stickies in papermaking paper breaks caused by spots sticking to drying cylinders blinding of forming wires and felts build up of tacky material on machinery paper defects which can cause problems for printers UPM 18 81

82 Size Distribution of Macrostickies in deinking Process Sticky Area Typical size distribution Unfavourable size distribution Ideal size distribution Particle Size [µm] Good performance of cross-linked dispersion adhesive and poly-urethane hotmelts UPM 19 Deinkability of flexo printed papers. Flexographic inks use water as the carrier and alkali soluble acrylic resin polymer as the binder Conventional deinking process involves alkaline pulping hydrophilic character of the ink aggregates small particle size distribution (0.5 3 µm) tendency for redeposition onto / into fibres Flotation process is totally unefficient Washing process transfers the problem to water UPM 20 82

83 Deinkability of flexo printed papers. Brightness, % Pulper newsprint brightness target Flotation % Flexo (60 % ONP - 40 % OMG) Contamination of the furnish UPM 21 Deinkability of flexo printed papers. Contamination of process water UPM 22 83

84 Some improvements In the frame of INGEDE CTP Flexo Task Force, new experimental flexo inks have been developped: clearly better deinkability than standard flexo inks optimum deinking process conditions towards neutral pulping but results still lower than with offset deinked pulp usage limited to standard Newsprint printing performance to be validated during a 6 month printing trial at HQP with Sun n 7 ink (08/06) UPM 23 Deinkability of Digital print: Toner Risk for high speck contamination of the pulp: too large particles to be removed by flotation and poor toner detachment (hairy particles) Hairy particles prevent attachment to bubbles during flotation but printing conditions can be found which give both a good toner adhesion & a good deinkability (INGEDE CTP Digideink) UPM 24 84

85 Deinkability of Digital print: inkjet prints Water based inkjet prints: main part of Digi prints same problem as flexo print Hotmelt inkjet print: stickies again! UV cured inkjet print: dirt specks contamination ( µm) UPM 25 Chapelle Darblay experience Stickies = one of the biggest problem associated with recovered papers, because of major adverse effect on productivity, with levels of up to 10% reduction in productivity Flexo print: some isolated incidents with UK or Italy recovered papers deliveries. Most of our furnish is coming from France but a problem for magazine production, especially in UK and Italy where flexo print share can be > 10%. Digital print: not really a problem in a newsprint mill, where office papers share is 5 %. but a problem for magazine or fine paper production UPM 26 85

86 If recyclability is to be improved Active cooperation is required between all the members of the paper chain: ink manufacturers printing press manufacturers printers and publishers adhesive manufacturers converters paper makers recovered papers sorting plants UPM 27 86

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89 Recherche et évaluation de la recyclabilité Research and Assessment of Recyclability Benjamin Fabry 89

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91 Centre Technique du Papier Recherche et évaluation de la recyclabilité Benjamin FABRY Séminaire INGEDE "Perfectionner le recyclage des produits imprimés" 5 octobre 2006 Hôtel Concorde S t Lazare, Paris Ingede Seminar - Paris / BF / 05/10/06 1 Guideline of the presentation Introduction Recyclability evaluation Example of Research programme Conclusions Ingede Seminar - Paris / BF / 05/10/

92 Introduction CTP is a Research Institute proposing Collective / customised research Technology transfer Private contracts (R&D, services, analysis) CTP's Mission To develop and transfer knowledge To innovate the pulp, paper, board and associated industries To improve their productivity and competitiveness CTP is ~150 employees and is located in Grenoble and in Douai (printing activities) More details available on our website: Ingede Seminar - Paris / BF / 05/10/06 3 Introduction Paper recycling Paper itself is a recyclable material During converting, some products can be applied Wax, adhesives, plastics, ink, etc During recycling, they must be removed to produce a new material for several reasons: Some of them can affect the runability of paper machine Some of them can affect the cleanliness of the final product Ingede Seminar - Paris / BF / 05/10/

93 Introduction Paper recycling Recyclability of graphic products mainly referred to Ink removal Deinkability Contaminant removal mainly in reference to removal of adhesive materials Stickies problems Are these products a source of limitation to the increase in the use of recycled fibres? Evaluation of recyclability Eco-conception approaches Improvement of recycling process through R&D activities Ingede Seminar - Paris / BF / 05/10/06 5 Guideline of the presentation Introduction Recyclability evaluation Example of Research programme Conclusions Ingede Seminar - Paris / BF / 05/10/

94 Recyclability evaluation Methods A lot of methods have been developed To determine the causes of problems in relation to recyclability / deinkability mainly for R&D activities Not really applicable to have a global approach Different methods and measures depending on the institutes and universities Harmonized, simplified and reproducible methods have been developed thanks to collaboration between the 3 main European Paper Institutes working in the area of recycling: INGEDE methods CTP (Centre Technique du Papier, Grenoble, France) PTS (PapierTechnische Stiftung, München, Germany) PMV (Fachgebiet Papierfabrikation und Mechanische Verfahrenstechnik, Darmstadt, Germany) Ingede Seminar - Paris / BF / 05/10/06 7 Recyclability evaluation INGEDE Method 11 Good deinkability High brightness (Ink detachment from the fibres and removal of them) and low speck contamination (cleanliness) Principle: Lab equipments to simulate deinking process (pulping & flotation) Controls performed on the samples generated Thanks to the data collected, Determination of oriented values for the main parameters to be taken into account Determination of a recyclability score by using threshold and target values for each parameters Ingede Seminar - Paris / BF / 05/10/