Keep print green upfront

　　New plate technologies mean the pre-press department has never been more sustainable, though questions over cost and performance remain, according to Steve Crowe.

　　Print still carries the stigma of an old, inflexible medium. It is an old medium - and proudly so - but accusations that it suffers baggage of its historic legacy are unfair. The industry is greener today than ever before. The use of paper is mostly to blame for the image crisis. (The wider public seems to miss the fact that printing is one of the only manufacturing sectors whose main input is 100% renewable and main output is 100% recyclable.) The chemistry used in printing also tarnishes the sector's image. Yet pre-press, like the rest of the printing workflow, has made huge strides to lift its game environmentally.

　　Industry commentator and former paper exec Phillip Lawrence reckons printing could well be the most successful of any manufacturing industry in reducing its impact. In his thesis for his Masters Degree at the University of Technology, Sydney, Barriers and Incentives to Ecological Modernisation: Case of the Australian Printing Industry, Lawrence writes: "As a general rule, the uptake of new technologies in the printing industry, not only in Australia but also around the world, has been the single biggest driver to an improved printing industry in regards to the environment."

　　While driven by costs and growth targets, the push toward better technology also has the distinct knock-on effect of improving a company's eco credentials.

　　"Most important have been advances such as CTP, which has reduced energy and chemical usage by as much as 95%. Automatic roller and blanket washing is less noticeable but its positive impact has meant a reduction of about 90% of volatile solvent use. The massive improvements in machine design have decreased electricity consumption by about 80% since the Kyoto base year," says Lawrence.

　　"The printing industry has acted out an almost perfect example of ecological modernisation theory, which describes a modernisation of society and how that might impact on the environment. In terms of policy opportunities, it means that in the case of printing, any incentives to apply new technologies will be positive to the environment.

　　"For any customer of the industry, the formula for environmental performance could not be more simple. If your printing company has the latest equipment, there is a fair chance they are doing well, they are competitive and they are resource efficient. Where some firms have gone the extra distance and instituted environ­mental management schemes within their business, such as ISO 14001, they are adding to their commitment."

　　Agfa business manager, pre-press, Koni Neuhofer is certain that the move to an environmentally friendly process is also business friendly. "Going green does not mean increased costs. If the overall benefits and cost savings are taken into account, the printer will always be in front. The printing industry as whole is constantly looking to work with more environmentally friendly products, and as such we have seen a real push in the request for green products. This applies to both plates and processors.

　　"Agfa is a major supplier to the entire printing industry, from the small to the very large, and we are seeing enthusiasm on all fronts for green CTP," he adds.

　　Steve Dunwell, managing director of manroland Australia,says environmental concerns actually motivate investment choices. "Based on discussions with, and feedback from, the market, smart business people understand that the environmental impact of their manufacturing processes
is no longer just a peripheral aspect of their overall operation, but a measure by which their customers are making investment decisions."

　　Pre-press vendors face the same pressures as paper makers to green up. Paper and printing companies feel the squeeze to ensure that virgin paper stocks are sourced from sustainable forests. That challenge has been taken up with gusto, with more printers turning to third-party credentials from the likes of FSC and PEFC. But green paper choices can run counter to eco-friendly pre-press ideals.

　　Sydney-based Focus Press has built a reputation as an environmental pioneer, and is a user of certified and recycled papers. It has found that while these papers are popular, they can create some difficulties in production. Pre-press manager David D'Astoli says: "We run a lot of recycled stocks and papers that are pretty rough, and our experience is that a lot of the process-free plates haven't been robust enough to accommodate all our different paper types.

　　"It's horses for courses. If we used nice paper all day every day, we'd be running processless plates," adds D'Astoli. The company now uses Xingraphics' FIT Xtra plates, but will test FIT eCO processless plates at some stage in the near future.

　　Plate talk

　　The positive influence of these new approaches to CTP is matched by a confusing number of new terms and jargon. Where do the differences lie between "processless" versus "chemistry-free" versus "low-chemistry" plates and processes? They all offer slower imaging, slightly lower resolutions and are limited on performance compared with conventional plates, but how do they differ from each other? (see box)

　　While they have different principles, but they all offer a means of reducing the use of chemicals and processing systems. And that can also mean lower costs, especially in association with other eco-focused production practices.

　　Presstek Asia Pacific sales director Tim Sawyer says: "Going processless or chemical-free is one way to reduce power costs, help improve the efficiency of pre-press by getting plates to press more quickly with less processes to go through, as well as help eliminate the need for waste removal. Printers today are looking at all areas of their production to improve their need to improve the environment.

　　"Going green in pre-press, as well as going green in the press room, helps printers be needful of reducing the impact on the environment," he adds.

　　Currie Group national CTP product manager Andrew Dunn sees more opportunities available for printers to cut their impact and their costs at the same time. "Workflow systems have improved. There is ink-optimising software available that can bring savings of 10-20% per job in some cases. And we have many RIPs that support soft proofing, which is becoming very popular. With the processing of plates, waste disposal and water/power consumption are significantly reduced. And with aluminium plates, you can recycle 100% of the plate material."

　　Kodak Australia marketing manager Anthony Harvey sees the move to environmental responsibility as a great motivator for new sales in CTP. "I think the local market is coping very well with the changes in the industry, and more importantly, coping well with the move to greener solutions. Printers now are looking at all aspects of their business, and now look to implement environmentally sustainable solutions across their whole business, not just in press and pre-press."

　　Green swap

　　Lionheart Printing has changed to Kodak Thermal Direct plates. General manager Steve Bugeia says: "It was mainly to cut out the processing side of things. We went with the [Agfa] Azura back in 2005, but this is a step further - now we don't have any gumming. They're slightly slower in imaging, but Heidelberg told us that we'll get a slightly longer run from them. I see the advantage in going totally chemical-free. It's good for us to be as environmentally friendly as possible."

　　Ian Martin of Ferag Australia points out that changing to low-process CTP does pose some problems, but the overall outcome is positive. "With the introduction of new plate technology, there also comes a number of limitations such as slower imaging speed, lower resolution, shorter run lengths, the plates are more sensitive to handling damage and they're less robust. They're more difficult to store and re-use, and have a higher cost to manufacture and subsequent higher purchase price.

　　"However, there are also benefits such as initial slightly lower equipment purchase cost - there's no need for a processing unit - the perceived environmental benefits and associated marketing message. What becomes a bigger focus is the workflow and its ability to automate preflighting, imposing, ripping, and output to many devices."

　　Fujifilm national manager, electronics, Steve Collyer says users are enthusiastic about the company's range of "eco-friendlier" plates. "The majority of our sales are green solutions because there are good savings to be had from going green. It doesn't matter what size the printer is."

　　Ferrostaal Australia, new agency for Fuji CTP in Australia, has the same experience. General manager, print, Gerard Wintle says: "Every printer is conscious of the environment and the impact the business has had in the past. Users look for 'clean' plates with minimal chemical usage, and that which is approved environmentally for waste disposal direct into water drainage systems."

　　While the jury's out on which is the greenest plate or most eco-friendly approach, there's no doubt that the great strides made in pre-press means printers can keep environmental ideals up front. The argument that pre-press should - and will - keep going greener is all but over. The real debate has moved onto cost and performance. Processless and chemistry-free have made inroads into SME printers, but certain sectors remain immune to their allure, for obvious reasons. Large printers find that greener plates aren't up to long runs. It'll take big breakthroughs before magazine or packaging work switches from conventional plates. But the cost of green CTP keeps dropping, while vendors such as Kodak, with its Trillian plate, take aim at high-volume printers.