1. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Utilize carbon calculator (PGG-CLOUD) to be PCR
for carbon footprinting in printing industry
SHIMIZU, Hirokazu
Nagata Lab., Waseda University Graduate School of
Environment and Energy Engineering (WEEE)
1

2. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Agenda
1. Self-introduction
2. Carbon Footprint for printing service worldwide
3. Development of carbon calculator “PGG-CLOUD”
4. Sample of carbon calculation
5. Utilize “PGG-CLOUD” to learn LCA basics
6. Utilize “PGG-CLOUD” instead of PCR
7. Special schematization in Thai printing industry
2

3. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Self-introduction
SHIMIZU, Hirokazu (May 19th 1967)
President, Shimizu Printing Inc. (March 1996～)
Qualification
Specialization in UV curing technology for graphic arts
Specialization in Material Flow Cost Accounting (MFCA) for printing
Specialization in Life-cycle approach (LCA, LCC) for printing
Pioneering achievement
Development of “UV Waterless High-definition Printing method” for
paper and plastic
Schematization of “Printing service LCA” in the viewpoint of
LCCO2 and Integrated LCA
Education
Doctoral program, Waseda University Graduate School of
Environment and Energy Engineering (anticipated to graduate
March 2012)
MBA program, University of Dallas (graduated in 1992)
Educational department, Waseda University
3

4. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Self-introduction (cont’d)
Research Achievement
Title Journal/Conference Year Author
Integrated LCA for Printing Service in an Eco Design 2011 Dec. 2011 SHIIMIZU Hirokazu,
emerging country NAGATA Katsuya,
HANSUEBSAI Aran
Integrated LCA approach for Printing Service by Japanese Society of Printing June 2010 SHIIMIZU Hirokazu,
Environmental Load Point Science and Technology NAGATA Katsuya
Paper
The comparison of paper-based book and Japanese Society of Printing May 2010 SHIIMIZU Hirokazu,
electronic book from the viewpoint of LCCO2 Science and Technology NAGATA Katsuya
Establishment of quantitative assessment Japanese Society of Printing Dec. 2009 SHIIMIZU Hirokazu
method for Printing Service Science and Technology
Introduction to Eco-design and Eco-design case Malaysia National LCA Dec. 2010 SHIIMIZU Hirokazu
study Seminar (Malaysia)
Life-cycle analysis of printed products Carbon Footprint in Printing July 2010 SHIIMIZU Hirokazu
Industry (Thailand)
Carbon offsetting from LCCO2 analysis by UV 123rd Spring Workshop by June 2010 SHIIMIZU Hirokazu
Oral waterless hi-definition printing method Japanese Society of Printing
Science and Technology
Establishment of Printing Service LCA to 6th LCA Japan Forum Dec 2009 SHIIMIZU Hirokazu,
propose environmental-conscious solution Seminar AKAGI Shuichi
LCA analysis of Paper-based package 4th LCA Japan Forum Mar 2009 SHIIMIZU Hirokazu
Seminar
4

5. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Self-introduction (cont’d)
Award
Encouraging prize from Japanese Society of Printing Science and
Technology in 2011
“UV Waterless High-definition Printing method”
Best paper from Japanese Society of Printing Science and
Technology in 2010
“Establishment of quantitative assessment for Printing Service”
Chairman’s award (2nd best) from 6th LCA Japan Forum in 2010
“Establishment of Printing Service LCA to propose environmental-
conscious solution”
Extra activities
Energy and Nuclear committee, Japan Chamber of Commerce
FIT for Renewable Energy committee, Ministry of Economy/Trade
/Industry (METI)
Policy adviser, Japan Chamber of Commerce
Environment committee, Tokyo Chamber of Commerce
Expert, ISO 130 (Graphic technology) WG11 (Environmental impact
of printed products)
Carbon Footprint committee, Japan Federation of Printing Industry
5

6. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Carbon Footprint for printing service worldwide
International Standardization of Carbon Footprint (CF)
ISO TC130 (Graphic technology) WG11 (Environmental impact
on print media products)
27 countries participate to draw up a set of rule for CF
Current draft will be ISO16759 sometime next year
France, Germany, Japan, Sweden, UK, USA play major roles
Dr. Aran is an expert from Thailand (Head of ISO committee in THA)
Leadership competition of “top carbon calculator” worldwide
France tries to take a position at central axis and form consortium
Germany scrambles to catch up France
Japan has no strategic plan
Thailand can form “Asian Consortium” as one of the printing
centers in the world
6

7. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Carbon Footprint for printing service worldwide
Comparison of system boundary (General/ISO/Nations)
Material/
Stage General ISO FRA GER JPN
Process
Paper ○ ○ ○ ○
Raw material
acquisition
Ink ○ ○ ○ ○ ○
Plate ○ ○ ○ ○
Prepress ○ ○ ○ ○
Press ○ ○ ○ ○
○
Production Cleaning agent ○ ○ ○ △
Dampening water ○ ○ ○ ○
Postpress ○ ○ ○ ○
Delivery Delivery ○ ○ ○ ○ ○
Use Usage at home ○ × × × ×
Incineration × × × ○
Waste/Recycle ○
Recycling × × △ △
Employee
Corporate commuting & sales
activities × × ○ × △
travel
7

8. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Carbon Footprint for printing service worldwide
Sample of carbon calculation (Books, 152*228*15mm, 5000copies)
Material/Process FRA GER JPN kg-CO2e
Paper 3738 4053 3890 6000
Commuting&travel
Ink 104 61 48
5000 Recyclying
Plate 211 121 214
Incineration
Prepress 221 351 4000
Delivery
Press 248 459 Postpress
Cleaning agent 998 32 - 3000
Dampening
Dampening water 25 5 Cleaning agent
2000
Postpress 137 285 Press
Delivery 334 65 44 1000 Prepress
Incineration - - 26 Plate
Recycling - -119 72 0 Ink
Employee FRA GER JPN Paper
commuting & 283 - 87 -1000
sales travel
Total(kg-CO2e): 5668 4844 5481
8

9. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Development of PGG-CLOUD
“Printing Goes Green based on Clouding” is developed
to calculate CO2e for printing service
modified through joint research with Chulalongkorn Univ.
Quantification procedure can fit together with ISO code
Quantification logic is ahead of other calculators
Calculation samples is provided for appendix of ISO code
Technical back up from Standardization is expected
9

10. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Development of PGG-CLOUD (cont’d)
Advantages of “PGG-CLOUD” utilization based on life-
cycle approach (LCA and LCC)
Utilize to improve procurement management
Carbon calculation to detect and replace material from the
viewpoint of environmental load and cost performance
Utilize to improve production process management
Carbon calculation to detect defective process from the viewpoint
of environmental load and cost performance
Utilize to edge sales competition
Carbon calculation for Carbon offsetting or Carbon Footprinting as
marketing tool
10

11. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Development of PGG-CLOUD (cont’d)
Sensitivity analysis: Case study at Chulalongkorn Univ.
(Textbooks, 190*260*6mm, 500copies)
Normal practice Best practice kg-CO2e
Material/ (Offset printing) (Print on Demand) 2500
process
kg-CO2e % kg-CO2e %
Paper 587.591 26.63 390.926 31.91
Ink 51.199 2.32 4.153 0.34 2000
Plate 427.810 19.39 0.000 0.00 45.5%
Additives 3.340 0.15 0.000 0.00 reduction
Design/editing 293.981 13.32 293.381 24.00 1500 Disp./Rec.
CtP 104.680 4.74 0.000 0.00 Delivery
Press 418.180 18.95 324.038 26.45 Production
Postpress 164.862 7.47 164.862 13.46 1000 Material
Water 0.007 0.00 0.000 0.00
Delivery 9.890 0.45 9.769 0.80
Disposal 133.026 6.03 34.876 2.85 500
Recycle from 1.174 0.05 1.174 0.10
household
Recycle from 10.726 0.49 1.187 0.10 0
factory
Normal Best
Total: 2206.466 100.00 1224.966 100.00
11

12. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation - Substrate
12

13. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Material flow
13

14. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Material flow (cont’d)
<Sustrate-1>
→ 40% incineration from household 37.821 × 25 gsm ÷ 190 gsm → 4.976 kg (coated layer to be burned)
109.816 g/sheet → 68.880% → 94.551 kg (Product) → 60% recycle from household → 56.731 kg
Actual: 1,250 sheet 137.270 kg → 31.120% → 42.718 kg (Non-Product: trimmed off at factory) gsm for Substrate-1
Make-ready: 150 sheet 16.472 kg
Total: 1,400 sheet 153.742 kg gsm for coated layer
<Sustrate-2>
→ 40% incineration from household 870.832 × 0 gsm ÷ 80 gsm → 0.000 kg (coated layer to be burned)
44.222 g/sheet → 65.641% → 2,177.079 kg (Product) → 60% recycle from household → 1,306.247 kg
Actual: 75,000 sheet 3,316.645 kg → 34.359% → 1,139.566 kg (Non-Product: trimmed off at factory) gsm for Substrate-2
Make-ready: 3,000 sheet 132.666 kg
Total: 78,000 sheet 3,449.311 kg gsm for coated layer
Product weight: 94.551 + 2,177.079 + 17.411 + 9.120 + 8.071 = 2,306.232 kg → → 40% incineration from household 922.493 kg
(Sub-1) (Sub-2) (ink) (hot-melt) (PP film) → → 60% recycle from household 1,383.739 kg
Product weight to be delivered: 2,306.232 + 9.36 → 2,315.592 kg
(P-weight) (wrapping paper)
Recycle from factory: 16.472 + 42.718 + 132.666 + 1,139.566 → 1,331.422 kg
(Sub-1) (Sub-2)
Recycle from household: 56.731 + 1,306.247 + <( 17.411 + 9.120 + 8.071 )> × 60% = 1,383.739 kg
(ink) (hot-melt) (PP film)
Incineration from household: 4.976 + 0.000 + <( 17.411 + 9.120 + 8.071 )> × 40% = 18.817 kg
(ink) (hot-melt) (PP film)
Ink for cover: 0.553 × （ 137.270 ／ 153.742 ） ＝ 0.494
Ink for text: 17.594 × （ 3,316.645 ／ 3,449.311 ） ＝ 16.917
18.147 17.411 kg
Total paper weight
Actual paper weight
Total ink weight
14

15. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Ink
15

16. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Ink (cont’d)
CO2 emission (UV ink, kg-CO2/kg)
Calculation
Material weight %
method
Black Cyan Magenta Yellow OP varnish
Energy for production 0.44 0.44 0.44 0.44 0.44 Cumulated
3EID & partly
Pigment (5-21%) 0.55 2.96 2.08 2.08 0.01
accumulated
Resin & Oligomer (66- 3EID & partly
2.24 2.17 2.17 2.36 2.69
Material 82%) accumulated
Photo initiator (8-10%) 0.48 0.60 0.60 0.60 0.60 3EID
Additives (3%) - - - - - Not evaluated
Waste loss(3%) 0.01 0.01 0.01 0.01 0.01 -
Total: 3.82 6.36 5.44 5.65 3.85
・Secondary data is organized especially for main materials having no emission factors
・Utilization of 3EID is effective when compositional characteristics is complicated
・Hybrid estimation by 3EID and accumulated is effective to upgrade 3EID-based data
16

17. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Ink trans.
17

18. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Water
18

19. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Water additives
19

20. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Plate
20

21. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Design/editing
21

22. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Plate output
22

23. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Press
23

24. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Postpress
24

25. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Delivery
25

26. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Waste
26

27. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Recycle
27

28. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Sample of carbon calculation – Result
Case st udy Thinking in Syst ems, 4P+240P 5000 copies
Category CO2e emission Ratio Subtotal Ratio
Substrate 3,889.836 72.10%
Ink 47.999 0.90%
Printing plate 213.905 4.00% 4,157 77.10%
Additives 4.860 0.10%
Other Materials 0.000 0.00%
Design/Editing 293.981 5.40%
Ct P 57.098 1.10%
Ct F 0.000 0.00%
Press 459.174 8.50% 1,096 20.30%
Postpress 285.250 5.30%
W ater 0.009 0.00%
Other Utility 0.000 0.00%
Other Transportation 0.000 0.00%
44 0.80%
Delivery 44.184 0.80%
W aste from household and factory 25.890 0.50%
Recycle from household 8.676 0.20% 98 1.80%
Recycle from factory 63.644 1.20%
T OT AL(kg-CO2e): 5,394.507 5,395
Procurement
Production
Delivery
Disposal/Recycle
0 1000 2000 3000 4000 5000 6000
kg-CO2e
28

29. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Utilize “PGG-CLOUD” to learn LCA basics
Primary data collection
Product/Non-product ratio for substrate
Ink usage forecast
Water usage forecast
Averaging electricity usage by facilities by actual monitoring
Transportation of materials and delivery of products
Secondary data selection
Emission factors from well-enhanced national database
Calculation of emission factors based on input/output table
Research is necessary for substrate
Research is necessary for disposal
Research is necessary for recycle
29

30. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Utilize “PGG-CLOUD” instead of PCR
PCR can be a good guideline for SMEs?
Reading thick rule book might be painful work
No concrete image just by reading rules
Learning from software is easier than reading a book?
Learning about LCA basics in stepwise manner from software
Maximize E-Leaning possibility to master LCA skills
Evaluation depends on reviewer?
No professionals to review printed matters in detail
No confusions because calculations are based on one scheme
30

31. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Special schematization in Thai printing industry
PGG-CLOUD in Japanese
31

32. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Special schematization in Thai printing industry
PGG-CLOUD in English
32

33. NAGATA Laboratory, Environment and Energy Engineering Department, Waseda University Graduate School
Special schematization in Thai printing industry
PGG-CLOUD in Thai
33