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Developing a best practices e-tool for reducing VOCs emissions in the European printing SMEs industry according to BATs (BATsGPRAH)
Date du début: 1 janv. 2009, Date de fin: 31 déc. 2011 PROJET  TERMINÉ 

Background The European Graphic sector makes a significant contribution to the European economy; it is formed by more than 106 000 enterprises with 1 281 478 employees and a combined turnover higher than 125 billion euros. The sector is characterised by many small and medium-sized companies. Roughly 95% of graphics enterprises employ less than 20 workers. In the organisational structure of these SMEs there is not usually a specific person responsible for environmental management. Usually, the person in charge of environmental issues is simply the production chain manager who will have technical, but not necessarily environmental expertise. This means that there is a general lack of skills and capacity within individual companies to deal with environmental questions and legislation. The environmental performance of the sector as a whole suffers as a result. At the same time, the industries in this sector have an important environmental impact notably from waste and pollution coming from printing inks, varnishes, dampening solutions and cleaning agents. Volatile organic compounds (VOCs) from solvents are a notable contributor to climate change, particularly from the many ‘sheet-fed offset’ companies. A Surface Treatment Solvents BREF outlines the best available technologies for the reduction of the environmental impact of these products. Objectives The main objective of the BATsGRAPH project was the development of an eTool to support graphics sector SMEs in implementing the Best Available Techniques (BATs) for reducing volatile organic compound (VOC) emissions derived from surface treatment using organic solvents. The project aimed to provide a useful tool for graphic arts industries to fulfil the European Directives: a) on the limitation of emissions of volatile organic compounds due to the use of organic solvents in certain activities and installations (1999/13/CE); and b) concerning integrated pollution prevention and control (IPPC) (2008/61/EC) in competitive conditions. The specific objectives were: To spread understanding and awareness of the contents of the BREF - Reference Document on Best Available Techniques - on Surface Treatment Using Organic Solvents to SMEs in the graphics industry; To compile the most advanced knowledge about successfully implementing BATs and to disseminate this to countries with less environmental and technical level (Spain, Eastern Europe); To extend the use of BATs for the industrial graphic processes included in the BREF across SME printing companies; To minimise the environmental impact of the printing industry, notably by reducing the VOC emissions derived from using organic solvents; To reduce health risks for printing workers.Results The BATsGRAPH project successfully developed specific information, awareness and tools to support SMEs in the graphic printing sector to implement the requirements of the IPPC Directive and the BREF document for the use of surface treatment solvents. Even though the companies are too small by themselves to be subject to these regulations, encouraging them to implement best practice can bring them economic savings and significantly reduce the environmental impact of the sector as a whole. The project conducted an initial study of the printing activities and implementation of BATs by SMEs in the graphics sector. An electronic questionnaire was developed focussing on three types of printing -: off-set, flexography and gravure - and 17 BATs. The team analysed the 431 responses received finding that only 10% of the SMEs were aware of the existence of the BATs and that focus should be given to the off-set printing companies. The team confirmed that experiences developed in the Netherlands were the best for dissemination to the other participating countries – Czech Republic and Spain. The team compiled definitions of the optimal methodologies for implementing some of the most important BATs for the sector, such as using vegetable inks, replacing isopropyl alcohol, and use of ceramic, metal and hydrophilic distributing and plate rollers. The methodologies cover basic conditions, maintenance and actual implementation of new equipment, and are designed to require minimal investment from the SMEs. A best practice guide was produced. The main output of the project was the eTool through which users can see step-by-step implementation of best practices and access tools to support them in doing this themselves, including critical explanation, printing forms and reporting. It also provides SMEs with an environmental control module which sets out the indicators with which they can measure and record environmental improvements. The project worked with three companies in each country to test implementation of the BATs based on the simple instructions developed in the eTool. The results from the nine companies demonstrated that the BATs improved the quality of printing production, reduced or eliminated use of isopropyl alcohol in the dampening solution, and showed equal quality printing from vegetable inks. Implementation reduced emissions of VOCs and showed that ISO 12647-2 is achievable for SMEs with limited resources. The tests also enabled optimisation of the eTool, which is supported by a manual on the Technical Best Practices and an on-line forum. After dissemination, the project team estimates that 10 700 SMEs of the sector received information about the project. It is hoped that more companies will follow the lead of the nine companies that participated in the project and that in years to come many companies will have used the BATsGRAPH tools to improve their environmental performance and reduce their costs. If 10% of the SMEs implement the BATs covered by this project, VOC emissions should be reduced by 2 526 tonnes per year. Further information on the project can be found in the project's layman report and After-LIFE Communication Plan (see "Read more" section).

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