Heatset Web Offset Printing

The following is intended to provide concise guidance for the industry to reduce emissions of volatile organic compounds (VOCs). It should be noted that in the majority of cases, the recommendations are based upon an either/or approach rather than for all to be undertaken. Offset (lithography) is the most widely used form of printing. It refers to the use of a rubber blanket to transfer the image from the plate to the substrate, and relies on the printing or image-area as being ink receptive and water-repellent. Depending on the type of substrate or products printed, the offset process is further divided into sub-processes; sheet-fed, heatset web and non-heatset web (coldset). Only heatset web offset printing is included in the directive. Activities covered in this guidance: Printing Drying Cleaning Printing Process: Offset inks are not volatile and only give rise to VOC emissions when heatset dryers are used, with emission at the stack. The main source of fugitive emissions arises from the evaporation of the dampening (fountain) solution which often contains isopropanol (IPA). IPA is added to the dampening (fountain) solutions in differing concentrations, the concentrations being determined by the type of press and the characteristics of the work to be printed. In sheetfed offset the concentration varies between 10 and 15%, in webfed offset between 8 and 15%. Except in the case of small sheetfed presses, the dampening solution is generally kept in a refrigerating unit next to the press. The dampening solution is continuously pumped towards the press, the excess returning to the container via an overflow. The concentration of IPA in the container is measured continuously. IPA is added automatically when the concentration diminishes. Unabated Situation: IPA is added to the dampening solution to a safe concentration, which allows all jobs to be printed without further adjustment. In many cased this concentration is used for all presses in the plant. Abated Situation: The IPA concentration is adjusted to the specific needs of the press and the job at hand, or a substitute is employed. Recommendations 1. Reduce IPA concentration as far as practicably possible 2. Substitute IPA 3. Apply waterless offset Reduce IPA concentration as far as practicably possible Reduce unnecessary evaporation: Keep containers with dampening solution and IPA closed. During lengthy press stops allow the dampening solution to return from the press to the container Regularly check the automatic IPA concentration measuring system. Check the manual measuring equipment for IPA and apply the rules for compensation for temperature properly. Cool the dampening solution (generally built in). Reduce IPA concentration: Experiment with lower IPA concentration. Where possible allow different concentrations on all the presses. Adapt machinery: Good maintenance of the rollers in the dampening system. Applicable to All plants All plants Exceptional cases only

Apply ceramic dampening rollers or rollers of a hydrophilic material.

The operator should choose the options most relevant for their situation. 1. Substitute IPA Additives, such as glycol ethers exist which allow lower IPA concentrations in the dampening system. They are added in concentrations of circa 1% to the dampening solution. The user should note that these additives can also represent a VOC emission. 2. Apply waterless offset Waterless offset is a printing technique that needs no water to ensure that the ink only covers the image carrying parts of the plate. The plates and inks are of a special make and patented. Existing presses may be changed to waterless offset, but this is complicated and expensive as it also involves considerable changes to the inking system. The technique has some advantages over normal offset, as the demanding print quality is easier to attain and make ready is faster. However, the process is not the cure for all IPA emissions. Heatset Drying: Normal offset inks dry through adsorption in the paper and oxidisation, which tends to be a slow process. Therefore, in fast web offset on non-absorbant paper, often, forced drying systems with special inks are used. The hot air causes the evaporation of mineral oils from the inks leading to VOC emissions. As the dryer extracts air from the press room, the waste gases also tend to contain some IPA and cleaning solvents. Recommendations 4. Incineration of waste gases meeting emission limit values specified 5. Limitation of fugitive emissions to 30% of solvent input 6. Condensation or biological treatment of waste gases 3. Incineration of waste gases meeting emission limit values specified Incineration of waste gases is the most appropriate method of reducing the emissions from heatset plants. In general it does not only reduce the VOC emissions but also takes away potential odour problems. Three different incineration techniques can be used; thermal, catalytic and regenerative incineration (see the section on abatement for further information). 4. Limitation of fugitive emissions to 30% of solvent input The target of 30% is demanding for heatset plants. The only way in which a heatset plant can reach the required 30% fugitive emission limit is by a combination of the following measures: Successful implementation of recommendation 1 or 2 (reduction of IPA emissions) Successful implementation of recommendation 9 (use of low volatility cleaning agents) 5. Condensation or biological treatment of waste gases Both techniques can be used as an alternative to incineration. Although they could be cheaper, there are disadvantages. For example, condensation is likely to be less effective in reducing VOC emissions, and nuisance from odour problems may persist. For larger plants the emission limit of 20mgC/Nm3 may not be achievable. Cleaning presses and ancillary equipment: Ink carrying parts of the offset presses are cleaned with solvents. These give rise to VOC emissions. Parts of the dampening system may be cleaned with water and water soluble cleaning agents, and these may give rise to water pollution. In large printing plants, where most of the cleaning is done automatically, large amounts of used cleaning solvent arise. Applicable to All plants covered by the directive All plants covered by the directive Alternative to incineration

Recommendations 7. Spray and clean with care 8. Do not throw waste cleaning solvent over used rags or wipes 9. Use cleaning solvents with a flash point >55C 6. Spray and clean with care

Applicable to All plants All plants All plants

When cleaning by hand, the cleaning agent is sprayed onto the contaminated surfaces. It is recommended to deliberately limit the amount of cleaning agent to what is strictly necessary and to use the rags and wipes intensively. This helps to reduce the consumption of cleaning agent and ultimately the emission of VOCs. Dispensing cleaning agents with a plunger type can is a good method.

7. Do not throw waste cleaning solvent over used rags or wipes

Self evident

8. Use cleaning solvents with a flash point >55C

The evaporation of solvent during cleaning can be reduced, by using higher flash point solvents. As high flash point solvents may not be as effective and efficient, a small amount of traditional cleaning agents will also be necessary Other issues to be aware of: In offset printing there is no need to employ halogenated solvents for cleaning. Some users have experimented with high boiling solvents or vegetable cleaning agents. High boiling solvents and vegetable cleaning agents (VCA), show even less evaporation than solvents with flash points over 55C. Working with these should be tried seriously, obviously taking into account any HSE issues, as some VCAs contain a variety of ingredients. . The information for this sector was provided by INTEGRAF. Contact INTEGRAF for more extensive information on Printing and the Environment.