2008 Environmental Reward
Eighth Annual FTA Environmental Excellence Awards Recognizes Three Companies
Each year, the Flexographic Technical Association (FTA) recognizes members of the flexographic community for outstanding efforts in achieving a cleaner environment. The Award Program recognizes facilities that have undertaken the risks of innovation, served as pioneers in flexography and improved the environment in the process.
Flexographic Technical Association (FTA) has the great pleasure to honor three companies in this year's Environmental Excellence Award program. Metro Label Co. Ltd. in Toronto, ON, Canada was recognized in the Process Improvement category. Plastic Packaging Inc. in Hickory, NC took Innovative Technology, while C & H Packaging in Merrill, WI earned an Honorable Mention in Process Improvement.
Companies are recognized through this prestigious competition because of their efforts in developing innovative processes, products and management approaches that have had a positive impact on the environment. Such efforts include, but are by no means limited to: measures to reduce waste, procedures to prevent pollution, policies that protect worker/employee safety and technological innovations that have helped make their facility more environmentally friendly. Applications are evaluated based on environmental benefits, other benefits, commitment and leadership and relevance to the industry and others.
"It's exciting to see companies go beyond mere compliance and get creative in how they meet the sustainability challenge. They are setting wonderful examples for the rest of us to follow," commented one of this year's judges Michael Rogovein, chief engineer, Tension Envelope Corp.
Built for the Environment
Established in 1974, Metro Label Group is a leading manufacturer of pressure-sensitive labels. Metro Label is a family-owned and operated business with four locations in North America, including its headquarters, Metro Label Co. Ltd. in Toronto. The company's commitment to building healthy, long term relationships with its customers and employees also applies to the environment.
When Metro Label began planning a building for its headquarters, environmental concerns ranked high on the list of priorities. The LEED (Leadership in Energy and Environment Design) standard was used in the planning, design and construction of the new facility and Canada Green Building Council awarded Metro Label LEED Certification. The facility includes a recycling area, and staff has implemented a waste management plan, which resulted in diversion of 54 percent of construction waste from the landfill. An estimated 21 percent of the building material value was comprised of recycled content. Another 37 percent of the materials were sourced locally and renewable materials were used wherever possible.
In the area of water conservation, Metro Label implemented several programs. The company used drought-resistant vegetation for landscaping. It installed a 10.9 cubic meter rainwater collection cistern for flushing ultra-low and dual-flush toilets. A storm-water treatment unit processes precipitation to remove 89 percent of the total suspended solids and 55 percent of total phosphorous before it leaves the site.
Metro Label also addressed energy efficiency. The HVAC system includes energy and heat recovery ventilators, which capture heat and transfer it to the fresh air supplied to the plant. Essentially, press exhaust is used to heat the building in the winter. The lighting design provides for reduced lighting power density and occupancy sensors for lighting control. Increased insulation throughout the building, along with high performance double glazed argon-filled windows reduces energy loss.
The results of Metro Label's efforts include a remarkable energy efficient operation, with a decrease of more than 45 percent in gas and electricity consumption per square foot (combined process and building) when compared to its previous manufacturing facility in Toronto.
In the prepress and pressroom, Metro Label continues its environmental philosophies and employees' green technologies. They utilize solvent-free plate developing technology. Dry media anilox roll cleaning is used in place of solvent-based parts cleaning equipment. More energy-efficient electronic ballasts are being used on its UV presses. The company offers clients sustainable packaging solutions such as PLA (polylactic acid) films which are made from 100-percent renewable resources (corn), are biodegradable and compostable.
By investing in LEED construction and implementing cleaner print processes, Metro Label hopes to stimulate green competition by creating a standard for the printing industry to be more environmentally conscious with the hope that others in the industry will follow their lead. Metro Label is a proud provider of innovative solutions to its clients who are becoming increasingly aware of the environmental impacts of their purchasing decisions.
"Metro Label is an outstanding example of environmental stewardship, using a comprehensive approach to sustainability that encompasses their facility, processes and even the products they make," remarked David Lanska of Stork Cellramic, who helped judge the competition.
"Our team is very proud to be recognized as this year's environmental leader for the flexographic industry," said Vikram Lal, president, Western U.S. and Canada, Metro Label.
Blending In
Located in the foothills of the Appalachian Mountains within minutes of the Blue Ridge Parkway, Plastic Packaging Inc. maintains a deep-rooted commitment to preserving and protecting the environment. In 1995, while Americans were disposing 20 million tons of plastic products into landfills, Plastic Packaging began the development of a proprietary biodegradable film. The base polymer blend contains 10-percent recycled components, plus the biodegradable additive.
Significant studies support the effectiveness of the additive as a true agent in accelerating the degradation process, even after one month. This blend also translates to 200,000 pounds per year being recycled rather than going directly into a landfill. In addition, landfill volumes will diminish over time as their biodegradable film degrades to humus. Their biodegradable program also includes a down-gauging plan that targets a 20-percent reduction in polymer volume, resulting in another 500,000lb. reduction of waste going to a landfill.
Plastic Packaging developed a unique approach to abating the environmental impact of plastics in the waste stream. The nature of their additive provides a platform to pursue other markets such as food, pet food, hygiene, consumer disposables and proprietary medical applications.
Reaching All Aspects
C & H Packaging, the converting division of Appleton Performance Packaging, has been a leader in environmentally sound business practice in the flexo industry for many years. With 100 employees in its Merrill, WI facility, C & H provides high-quality flexographic printing and laminating to the flexible packaging industry.
C & H Packaging's environmental scorecard is comprehensive and impressive. It converted to water-based inks and 100-percent solid adhesives. In the prepress area, the company began in-house plate making to eliminate shipping and is now scaling up production of digital plates. It has a photopolymer solvent reclamation unit, which eliminates 1.25 drums (55 gallons) per eight hour shift. The firm saves approximately $250 per month by running it during off-peak demand hours. C & H Packaging also uses an ink splitter, which separates the liquid components of its printing press wash-up solution from the solids and creates a cake-like substance that can be landfilled. The liquid can be disposed of safely in the sewer system.
Press waste is recycled at the rate of approximately 432 bails (1,500lbs each) per year. More than 350,000lbs of plastic film is recycled along with an additional 4,380lbs of paper, 24,000lbs of corrugated board, old pallets and cores.
Lanska said, "C&H Packaging has a multi-tiered approach to improving its process in an environmentally sound way."
