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The Greening of the Industry Now!. Michael Keene President / CEO The John Roberts Company. The John Roberts Company History and Facility. Privately held company established in 1951 Current location since 1974 Modern 226,000 square foot facility State of the art green facility.
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The Greening of the Industry Now! Michael Keene President / CEO The John Roberts Company
The John Roberts CompanyHistory and Facility • Privately held company established in 1951 • Current location since 1974 • Modern 226,000 square foot facility • State of the art green facility
Recycling efforts at JR • The JR Sustainability Team is a cross-departmental group of employees • Currently working on a project to increase the amount of material we recycle
JR Environmental Stewardship • Our Policy – • The John Roberts Company is committed to managing all of its operations in an environmentally sound manner. • We involve our employees, our suppliers and our customers in the principle that to conduct business at the expense of the environment around us is simply unacceptable. • Through awareness, understanding, education, and action we are minimizing our intrusion on the environment.
Environmental Management System (EMS) • Re-Use and Reduce • Paper • Environmental Materials • Solvent Recycler & Disposal • Energy Reduction • Ink • Sustainable Certifications • Sustainable Offerings • Marketing & Education
Paper Re-Use • Recycling Approximately 5460 tons • Wood use: minimum 96,768 trees • Total energy: 191,232 million BTU or enough to heat 2101 homes / year • Greenhouse gases: 28,742,663 lbs CO2 or 2610 cars / year • Wastewater: 88,788,790 gallons • Solid Waste: 11,405,264 lbs or 407 garbage trucks
Minimize Wasteadds to your bottom line $2206.80 - Sustainable Size $700.00 - Post Press Cutting Savings $2908.80 – TOTAL SAVINGS Plus 2710 lbs. saved from going into the waste stream.
Solvent Recycler & Solvent Disposal • RE-USE • 50 drums of waste solvent - sheetfed area. • Recovered & Reintroduced 10 drums of solvent back into the production areas • Reducing our recycling costs and solvent purchases. • $AVING$: • Minimum of 85% of hazardous waste disposal will be eliminated by onsite recycling • REDUCTION: • Solvents shipped to outside vendors for disposal • Being used in a fuel blending process and therefore kept out of any landfill • Since last year - 60% reduction in our solvent disposal.
Energy Reduction • Reduce • T8 Fluorescent Energy Saving Lighting • Partnered with Xcel Energy • Optimized compressed air system • Regenerative ThermalOxidizer (RTO) • Burns excess VOC Provides energy • Reduces overall energy consumption
Energy Reduction Re-U$E – Windsource Program • Customers indicate they want their jobs run on Wind Power • John Roberts - purchases additional Windsource Energy(sold in 100-kilowatt-hour (kWh) blocks) • Although it isn’t possible to separate energy by sources, you are participating in the production of goods made in part with renewable energy. • Dollar investment is relatively small - adding about 2% to a typical job’s cost • John Roberts purchases 10% of electrical energy on our own power grid • John Roberts is an EPA Green Power Partner
Materials Reduction - Carpet • Replaced 5,148 square feet of carpet • Saved 12,870 -10 oz. bottles from landfills • Used Nexterra carpet tile backing – made from 35% post-consumer content recycled water and soda bottles with an additional 50% from post-consumer recycled glass.
Soy-based Ink • Environment-friendly chemistry • Outstanding printing properties • Ink Systems, Inc We are now looking at ways to recycle / reuse our web process inks to reformulate black ink.
Varnish in Totes vs. Kits • Eliminate varnish kits • Last year : approx. 2000 kits used • 14 skids of kits! • JR in Totes vs. Kits will prevent • 2 tons of plastic from going into a land fill each year $5700.00 savings each year
Sustainable Certifications 1st Printer in MN to be TRI-CERTIFIED • JR is proud to be the 2nd printer in MN to receive FSC certification by Smartwood • SFI • PECF
Sustainable Accomplishments • Carbon Neutral • Recently completed scientific study of carbon footprint • No atmospheric net gain in carbon emissions
JR Environmental Achievements • Green Star Award • Best Workplace in America • Twice Received the Governor’s Award for Excellence in Waste and Pollution Prevention • Minnesota Environmental Initiative Award
JR Environmental Achievementscont’d • Industrial Environmental Achievement Award • Member PIM Great Printer Environmental Initiative • Member, Minnesota Waste Wise • Partner, Clean Air Minnesota
Initiatives Under Development • ISO 14001 • Incorporate into our ISO 9001 system
Water reduction in Prepress • New Plate Setter / Processor • Reusing water through watermizer • Reducing water consumption of over 250,000 gallons annually
Marketing and Education JR Notes - Environmental Issue Target goes GREEN with RED. Target ran their monthly employee newsletter on FSC coated stock supplied by JR. JR utilized Windpower as energy source to produce printed piece. JR Website - Environmental Section www.johnroberts.com JR Workshops – Environmental Symposium
Additional Initiatives • JR Employee Quality Recognition Program Sustainability Segment • Promotes Cross-functional green teams to exchange ideas and share learnings • Points based • Workout Facility On-Site • Employees do not have to travel elsewhere to exercise
Why Go Green? • Ownership with strong sense of environmental stewardship • Important to Employees • Makes good business sense • Differentiates our products and services • Increasingly a requirement of our customers
Our Environmental Plan • Develop an Environmental Management Plan; include an Environmental Policy • Identify products, processes or general areas that have a significant impact on the environment • Set up operational controls • Make changes in chemical products, processes or activities so as to reduce environmental impact • Checking and Corrective Action • Management Review
What can customers do? Costs? • Use Recycled &/or CoC certified paper • Use Wind energy • Adjust size of piece to best utilize sheet; less waste • Use online proofing system (Insite); save time and material • Cost impact of green printing: 2-10% • John Roberts continues to seek ways to keep costs controlled while reducing impact on environment
Prioritizing Green Options • Determine: • Desired end print quality (Bright white or earthy look) • Budget • Product availability • Printer’s green capabilities • Try what’s available • Recycled • Chain of Custody (FSC, SFI, PEFC) • Wind power alternative fibers • It’s more important to use options that are available to you rather than wait to find the perfect solution.
Chain of Custody Certification • Forest Stewardship Council (FSC) label can’t be used with any other CoC label • Sustainable Forestry Initiative (SFI) and Programme Endorsement for Forest Certification (PEFC) will allow labels to be used concurrently • In most circumstances, the logo approval process takes less than one day.
Sources: Regulations & Paper • Regulations • Printing Industry of MN • EPA (Minnesota and Federal) • Internet • Paper • http://www.fsccanada.org/fscpaper.htm • http://www.fscus.org/paper/ • http://www.sfiprogram.org/paperprinting.cfm • internet
Direct mail • Clean lists • Reduce amount of landfill waste due to undeliverable products being destroyed • Provide maximum deliverability • Run a Move Update to ensure most current address per Post Office regulations • Use recycled paper when possible • Do it all in one location: most projects can be handled at John Roberts, avoiding costly transportation charges incurred with outsourcing
UV coating • All UV inks and coating used at John Roberts are environmentally friendly • 0 Volatile Organic Compounds (VOCs) • Completely recyclable
Trees and Pulp • A minimum of 3 trees are planted for each tree harvested • Pulp sources • Hardwood (spruce & pine) • Softwood (maple & oak) • Non-tree sources • Fiber crops: hemp, kenaf, jute and flax • Agricultural Residues: sugar cane husk, cereal straws (barley, oat, wheat, rice, rye) • Textile and Cordage wastes: cotton and linen scraps, old rope • Wild plants: wild grasses, sisal, bamboo
Solar? • Any options are open for the future
What is deinking • Before recycled paper can be used to manufacture new ‘white’ grades of paper, the printing inks have to be removed to increase the whiteness and purity. A chemical process using alkali and detergents is used. The recovered paper is first dissolved in water and separated from the non-fiber impurities. The fibers are then progressively cleaned in order to obtain the pulp and during this stage the ink is removed. The greater the ink coverage, the more aggressive the de-inking process.
Adhesives • Adhesives used at John Roberts are VOC free