Industrial Energy Savings    

Printing

Compressed Air Best Practices interviewed Michael D. Manzella.  Mr. Manzella is a Senior Vice President, Environmental, Health, Safety and Quality (EH&S), and also the Chief Sustainability Officer for RR Donnelley (RRD).
Several days prior to our visit, during a cold winter evening, the lead air compressor in one mechanical room tripped off (apparently due to a fouled intake filter and low air flow through the machine). A crucial situation then developed: The "stand-by" unit did not start. Maintenance folks had to be called in to get a compressor running. That delay caused low plant air pressure, production curtailment and some defective product. They had yet to determine the conditions that caused the "no-start".
Energy efficiency means providing more services with less energy- this translates into an overall reduction in greenhouse gases (GHGs) and therefore a healthier environment. Energy efficiency is an obvious solution to a pressing problem, which is why Quebecor World is continuously searching for energy conservation opportunities; these include the implementation of efficient technologies, as well as the effective management of all energy sources (electricity, natural gas and propane).  
Pulp and paper production generates about half of its own energy needs from biomass residues and makes extensive use of efficient and clean combined heat and power (CHP), also known as cogeneration.
There are many facets to producing green print materials that extend well beyond paper. Not every printer has the same knowledge of green printing or the corporate commitment to uphold the highest environmental standards. Transcontinental is a true “green” partner that not only offers a broad range of recycled paper options, but also strives to bring environmental responsibility to every aspect of the manufacturing process.
There is no getting around it: printing presses use up a lot of energy, and large presses even more. A six-color Heidelberg Speedmaster XL105 with coating unit consumes–without technical enhancements–up to 560,000 kilowatt-hours of power to produce 36 million printed and coated sheets over the course of a year. But Heidelberg is working harder than any other company serving the industry to systematically reduce the energy consumption of every individual component of its sheetfed offset presses.
The primary objective of this case study is to illustrate the process in which industrial facilities can qualify for energy incentives on projects that reduce the energy usage of their compressed air system.
This article will focus on a compressed air system assessment done at a printing facility in Canada. The energy costs at the time, in Manitoba, were $0.025 per kWh and the installation was of just 65 horsepower of air compressors.
Most printing facilities use vacuum for one process or another.  I recently spoke with Jesse Krivolavek, (a vacuum system efficiency specialist with IVS, Inc.) about his recent adventures in the world of printing.
This commercial printing facility is located in the Northeastern part of the U.S.  Like most facilities, the plant has seen many changes over the years.