Case
Study
PRINTING INDUSTRY
Print Shops: Equipment Modification to Reduce Wastes
| Company | Jefferson County Public School Printing Department 809 Quail Street, Bldg. #1 Lakewood, CO 80215 |
|---|---|
| Person to Contact | Rick Rowe Telephone: (303) 982-2273 |
| Product or Service | Low volume printing services for Jefferson Co. Public Schools - 90-95% black inks. |
| Number of Employees | 7 |
| Waste Stream Targeted | Ink, Solvent emissions and waste |
| Original System | Conventional Small Offset Presses are used: an Itek 975 PFA Press and a Multi-Graphics 1250 (one-color). These presses run 5,000 impressions per hour one-sided (Multi- Graphics) to 8,000 impressions per hour double-sided (Itek), and require the use of oil or rubber-based inks. |
| New System (with P2 Modifications) |
Duplicators are used in place of the offset presses. Two new duplicators were purchased: a Risograph GR 3750 Duplicator and a Gestetner Duplicator 5380. These are used for low to medium-range one-sided, primarily one-color printing. These units take an original document, digitally scan the image, and transfer it to a master via a thermal imaging process. The master is biodegradable. Water- based ink is microprocessor-controlled and vacuum drawn from a cartridge, eliminating ink waste. Use of hazardous solvents for clean-up is also eliminated. The print drum can be quickly changed for color printing. Prints 8,000 impressions/hr. Can run 5,000 - 10,000 impressions/plate. |
| Cost Savings | |
| Initial Equipment Cost | Risograph GR 3750 Duplicator - $16,000 (manuf. suggested retail). Gestetner 5380 Duplicator - $15,000. |
| Material Costs | Total material costs for both duplicators: $10,000/yr, vs. $24,000/yr for offset presses, a material cost savings of $14,000/yr. |
| Waste Disposal Cost Savings | Waste disposal cost savings have not been quantified. However, JeffCo predicts a 90-95% reduction in generation of ink and solvent wastes. |
| Major Benefits | Savings of $14,000/yr in material costs. Maintenance costs are significantly reduced (but have not been quantified). Use of hazardous inks/solvents is eliminated, thereby reducing VOC and HAP emissions, worker health and liability concerns, hazardous waste generation, and associated regulatory requirements. Positive business image. Very little initial training is required; the duplicators are easy to operate, much like a copy machine. |
| Obstacles | Itek 975 and Multi-1250 offset presses are better for long runs ( 10,000 impressions) and multi-color one pass printing. A print drum must be changed in the duplicators to change colors, requiring multiple passes for multi-color jobs. |
| Source/Supplier | Gestetner 445 Union Blvd., Suite 112 Lakewood, CO 80228 Rep: Jeffrey Lopez (303) 989-4499 RISO (Frontier Business Products) |
| Time Since Implementation | 60 days (11/2/95) |
| Main Reason Implemented | Looking for alternatives for Multi-1250 presses due to increased
costs to repair/rebuild older machines. Reduce hazardous waste generation. |
| Key to Success in Making this P2 Modification | Vendor recommendations on state-of-the-art products/equipment. |
Created by Lighthouse Communications Group, LLC.
Edited for use on this site by Ronald Lee Still and posted with
permission of CDPHE.