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When reading about sustainability, it is easy to see the focus on the product design, the printing and finishing process, and the chemicals and materials used. These are the major facets confronted in the effort to be sustainable. Yet there are other concerns that can be addressed that relate to conserving the natural resources at our disposal. There is a need to recognize the related activities in our plants and offices which have an impact on the manufacturing processes and industrial wastes. The emphasis given to these efforts deserve attention in our quest to save the environment and conserve energy.
A major factor is not the operating but the maintenance of your plant and equipment. If print owners took the time to evaluate the nature of waste products generated by the processes and the normal functioning of the office, they would find that there is a thing to be said about prevention rather than disposal. How much more effective would it be to run a cleaner operation if the machinery in both office and plant were properly maintained?
How much less waste would be incurred if printing companies did not wait for signs that a part or parts were wearing, instead of practicing a program of replacing parts at the conclusion of a theoretical or estimated lifetime? How much less waste would be generated if jobs were properly described and checked prior to being sent to the pressroom, to make sure that all specifications were correct and complete?
These are but a few of the questions asked when auditing a printing business. Sure there is a need for using recycled materials, safer inks and solvents, and processes that generate lower wastes. But when have owners sat down to consider the factors that lead to excessive wastes? When have print shops determined that not all waste of paper, film, inks, and solvents are generated by the people on the line? Have the press personnel been given the right material on which to print, the correct ink colors and, without question, the correct copy?
To be sure, in most cases these deficiencies are not seen too often. However, they do occur, and all too often when one considers the waste of materials, inks, and time—let alone the overall product waste—that is not acceptable to a customer. Wastes are too often seen simply as defective products or by-products of the printing presses and finishing equipment. Check the activity before an order reaches the pressroom and see what is being passed through that can be prevented.
Pressing the Issue
Press maintenance is a question of time and expense. Properly maintained, a press will produce quality products with minimum waste, given that it is fed the proper and accurate information and materials. Scheduled maintenance allows for time during which production is not expected, and time has been given to adequately make parts changes, lubrication, diagnostic evaluation of the condition of the equipment, and remediation of any faults detected.
During this time, there are neither wastes generated, nor discharges of any emissions or wastes to the environment. As a result of this preventive maintenance, less waste and lower discharges should result when the press is put back into production. Every press should have a maintenance checklist, and periodic sessions scheduled for preventive maintenance. Is this taking place in your plant? Or do you wait until a press is down or there is a problem that needs urgent correction?
Preventive maintenance carries beyond the press and finishing equipment. When considering energy, maintenance stretches to all the air handling—heat and air conditioning—in the office and plant, as well as all the light fixtures and bulbs. Maintenance and replacement of components is critical to proper functioning and conservation of energy.
Waiting until the bulb burns out or the motors start to moan and groan is too late. Inefficient electrical motors, fans, and bulbs will chew up energy like there is no tomorrow. Proper scheduling of bulb and filter replacements, lubrication, and inspections can go a long way to minimizing the waste of energy and maintaining a proper workplace.
The key to the message is to trigger a realization that every printing plant and related office must take the time to realistically review all of its operations and determine the ramifications of any failure in any link of the chain on the environment of the plant and the community.
Printing firm owners should not relegate their attention to the printing press. Open that vista to include the work that precedes the pressroom, the effort that goes into making the presses and finishing equipment operate efficiently and the personnel performing in a safe and appropriate manner. Don't take anything for granted as the office, pressroom, and maintenance operations are all evaluated. They all, in one way or another, influence the generation of product and wastes in your printing company.
Fred Shapiro is the president of P-F Technical Services Inc. based in Silver Spring, Md., a technical and environmental management consulting company to the graphics arts industry. He is also a member of the PIA/GATF's "Solutions on Site" consulting network. Contact Mr. Shapiro at (301) 598-7949.
author: By Fred Shapiro