1. Nagata Laboratory, Waseda University Graduate School of Environment and Energy Engineering
Simplification of PCR for Printed products
Carbon calculation by10-selected item
Dr. SHIMIZU, Hirokazu
President, SHIMIZU PRINTING INC.
Visiting Senior Researcher, Waseda University Environmental Research Institute
Expert, ISO130 (Graphic technology) WG11(Environmental impact of printed matters)
1

2. Waseda University Environmental Research Institute
Motivations
1. Complicated PCR should be reformed
• Time-consuming work is big wall for SMEs
• Detailed calc. is not equal to “Sophistication”
2. New thought by new CFP program holder
• CFP should be utilized for “business”
• More than one PCR can exist for same product
3. New concept for SMEs
• Carbon calculator can be PCR
• Reduce manpower for calculating work
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3. Waseda University Environmental Research Institute
Agenda
1. Promotion of new PCR for Printing
• Select only 10-item for simplification
• Points of modifying current PCR
• Accuracy of PCR for Printing by case studies
• Conclusion of new PCR accuracy
2. Accuracy of existing PCR for Printing
• The difference by emission factors of paper
• The difference by calculation methods
• Conclusion of current PCR accuracy
3. Summary
• Magnitude of fluctuation of new/current PCR
• Utilization of CFP
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4. Waseda University Environmental Research Institute
1.Promotion of new PCR for Printing (cont’d)
Select only 10-item for simplification
(1)Substrate
NOT calculated
(2)Transportation for substrate
Water (dampening solution)
(3)Ink & varnish Additive (dampening solution)
(4)Transportation for Ink & varnish
(5)Plate (waterless printing)
(6)Transportation for Plate
Prepress(editing, designing, CtP)
(7)Printing process (waterless printing)
(8)Post-press process Material (glue, stitch...)
(9)Distribution Wrapping material for delivery
(10)Waste & Recycle
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5. Waseda University Environmental Research Institute
1.Promotion of new PCR for Printing
Points of modifying current PCR
I. Calculation method is unified for “cumulative”
II. Modelization for thickness of ink/varnish
III. Electricity usage = Rated output × fixed loading factor
IV. Loading percentage of truck is fixed at 50%
V. Calculate incineration by coated layer of paper only
VI. Printed products only by waterless printing method
VII.Avoid “scenario setting” of key items
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6. 1.Substrate (paper/plastic)
2. Trans. for Substrate (trucks/rail/surface/air)
Shimizu Printing Inc.
Raw material acquisition
3.Ink & varnish (conv./UV ink, OP varnish, Coating varnish)
4.Trans. for Ink & varnish (trucks/rail/surface/air)
5.Plate (for waterless printing)
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6.Trans. for Plate (trucks/rail/surface/air)
Points of modifying current PCR
7.Printing process (electricity for machines, lighting, air-cond.)
Production
8.Postpress process (electricity for machines, lighting, air-cond.)
1.Promotion of new PCR for Printing
9.Delivery (excluding packing materials)
Distribution
(cont’d)
10.Waste from household, Recycle from factory and household
Waste/
Waseda University Environmental Research Institute
Recycle

7. Waseda University Environmental Research Institute
1.Promotion of new PCR for Printing (cont’d)
Accuracy of new PCR for Printing by case studies (Paper package for DVD)
100000 copies
0 30000 copies 10000 copies 5000 copies
c 500 copies
c
# Item
kg-CO2e % kg-CO2e % kg-CO2e % kg-CO2e % kg-CO2e %
1 Substrate 2104.4 69.6 701.4 64.3 300.6 58.5 200.4 52.5 110.2 41.6
2 Trans. for Subs. 207.6 6.9 69.2 6.3 29.7 5.8 19.8 5.2 10.9 4.1
3 Ink&varnish 55.3 1.8 18.5 1.7 17.9 1.5 5.3 1.4 2.9 1.1
4 Trans. for Ink&varnish 0.2 0.0 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0
5 Plate 36.2 1.2 36.2 3.3 36.2 7.0 36.2 9.5 36.2 13.7
6 Trans. for Plate 0.1 0.0 0.1 0.0 0.1 0.0 0.1 0.0 0.1 0.0
7 Printing process 170.6 5.6 85.3 7.8 42.6 8.3 42.6 11.2 42.6 16.1
8 Postpress process 180.2 6.0 58.4 5.4 21.3 4.1 13.4 3.5 7.0 2.6
9 Delivery 25.9 1.0 11.4 1.0 3.8 0.7 1.9 0.5 0.2 0.1
10 Waste & Recycle 193.6 6.4 61.4 5.6 23.6 4.6 14.2 3.7 5.8 2.2
- Others 51.3 1.7 48.8 4.5 48.2 9.4 47.9 12.5 49.1 18.5
Total 3025.4 100.0 1090.8 100.0 514.0 100.0 381.8 100.0 265.0 100.0
Per copy 0.030 - 0.036 - 0.051 - 0.076 - 0.530 -
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8. Waseda University Environmental Research Institute
1.Promotion of new PCR for Printing (cont’d)
Accuracy of new PCR for Printing by case studies (Paper package for DVD)
100%
Others
Waste & Recycle
Delivery
75% Postpress process
Printing process
Trans. for Plate
50% Plate
Trans. for Ink&varnish
Ink&varnish
25% Trans. for Subs.
Substrate
100000
30000
10000
5000 0%
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9. Waseda University Environmental Research Institute
1.Promotion of new PCR for Printing (cont’d)
Accuracy of new PCR for Printing by case studies (Flyer from 300-500,000)
other items 10 items %
100
90
80
70
60
50
40
30
300
20
500
1000
10
1000
2000
2000
3300
5000
5000
0
5000
10000
10000
10000
10000
15000
20000
30000
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10. Waseda University Environmental Research Institute
1.Promotion of new PCR for Printing (cont’d)
Accuracy of new PCR for Printing by case studies (Booklet from 410-500,000)
other items 10 items %
100
90
80
70
60
50
40
30
20
410
500
1000
10
1300
2000
2000
2400
2700
4000
4500
5000
0
5000
9500
10000
10000
18000
18000
30000
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50000
10 100000

11. Waseda University Environmental Research Institute
1.Promotion of new PCR for Printing (cont’d)
Conclusion of new PCR accuracy
Carbon calc. by 10-selected item
Package
1.7% ～ 18.5% of “Others” by Shimizu Printing
Flyer
2.8% ～ 22.6% of “Others” by 18 cases
Booklet
1.7% ～ 27.8% of “Others” by 38 cases
New PCR has “missing piece” of carbon calc. result
Current PCR can provide absolute carbon calc. result?
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12. Waseda University Environmental Research Institute
2.Accuracy of current PCR for Printing
The difference by emission factor (EF) of paper
(1) Magazine, 210mm*297mm, 4P+44P, 4000copies
(2) Coated card for cover, 210gsm, UV4C+PP lamination
(3) Light coated paper for text, 127.9gsm, UV4C/UV4C
(4) EF of text is calculated by weighting 6 factories (48.2%)
(5) Max. EF=1.419kg-CO2e/kg, Min.=0.704kg-CO2e/kg
(6) Weighted EF=1.197kg-CO2e/kg
(7) Sensitivity analysis by different EF of Light coated paper
(8) What I use for text is Avg./Max./Min.?
Reference：JLCA-LCA database 2012yr.1st edition
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13. Waseda University Environmental Research Institute
2.Accuracy of current PCR for Printing (cont’d)
The difference by EF of paper (Magazine, 4000 copies)
kg-CO2e
+7.1% 2250 Recycle
Waste
2000 Delivery
-21.5%
Water
1750
1384.94 1541.192 Postpress
1500 Press
CtP
1250
Design/Editing
1000
913.137
Additives
750
Plate
Avg. E.F. 500 Ink
Max. E.F. 250 Paper
0
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14. Waseda University Environmental Research Institute
2.Accuracy of current PCR for Printing (cont’d)
The difference by calc. method
(1) Paper package for DVD, 130mm*130mm*9mm,
100,000copies
(2) Coated cardboard, 360gsm, UV4C+UVOP varnish
(3) EF is calculated by weighting 4 factories (86.8%)
(4) Calculated based on Cumulative method for
1,000-100,000
(5) Calculated based on Allocation method for
1,000-100,000 (allocation basis is based on paper input)
(6) Current PCR allows printers to utilize both methods
(7) Who can consider the difference between two methods?
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15. Waseda University Environmental Research Institute
2.Accuracy of current PCR for Printing (cont’d)
The difference by calc. method (Paper package for DVD)
Cumulative Allocation % (Allocation/
Copies
g-CO2e/copy g-CO2e/copy Cumulative)
1000 276.075 223.708 81.0
2500 126.353 113.372 89.7
5000 76.362 71.132 93.2
7500 59.739 59.276 99.2
10000 51.398 53.349 103.8
20000 41.328 44.457 107.6
30000 36.359 41.493 114.1
40000 33.880 40.011 118.1
50000 32.389 39.122 120.8
60000 32.199 38.530 119.7
70000 31.375 38.106 121.5
80000 31.291 37.789 120.8
90000 30.811 37.542 121.8
100000 30.254 37.344 123.4
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16. Waseda University Environmental Research Institute
2.Accuracy of current PCR for Printing (cont’d)
The difference by calc. method (Paper package for DVD)
300
250
200
Cumulative Allocation
150
100
50
0
1000 2500 5000 7500 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
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17. Waseda University Environmental Research Institute
2.Accuracy of current PCR for Printing (cont’d)
Conclusion of current PCR accuracy
Carbon calc. by different EFs
+7.1% ～ -21.5% compared to avg. data
Carbon calc. by different calc. methods
+23.4% ～ -19.0% compared to cumulative method
Current PCR has certain range of carbon calc. result
No absolute number from carbon calculation
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18. Waseda University Environmental Research Institute
3.Summary
Magnitude of fluctuation by new/current PCR
Min. Max. %
Current PCR 130
123.4
97.2 107.1
98.3
97.5
77.4
72.2 78.5
81
65
32.5
10-item(flyer)
10-item(Booklet)
Paper EF 0
Allo./Cum.
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19. Waseda University Environmental Research Institute
3.Summary (cont’d)
Utilization of CFP by simplification of PCR
a. Find “Hotspot(s)” to improve manufacturing process
and/or select eco-friendly material
b. Communicate with print-buyers (consumers) by
showing comprehensive internal comparison
c. Conduct many pilot projects to know efficiency of
CFP (environment impact assessment)
CFP should be utilized for sales growth and cost-cut, not for
academic experts to be satisfied
Simplification of calculation is extremely important to save time
and money, “Detailed calculation cannot guarantee accuracy!”
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20. Waseda University Environmental Research Institute
Thank you for your attention.
You can have a look at this presentation file:
http://www.slideshare.net/ShimizuHiro/edit_my_uploads
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