Waterless Printing Exceeds Japan’s New VOCs Regulations

Although volatile organic compounds or VOCs are relatively insignificant as direct greenhouse gases, they act indirectly by producing organic aerosols in the atmosphere, like ozone, which themselves are direct greenhouse gases.  This is why most of the industrialized nations are taking action to curtail VOC emissions.  New measures have been enacted in Japan joins and the European Union.  No such new regulations have been implemented in the United States.

In April of 2006 the national targets for VOC emissions reductions went into effect in Japan, the world’s second leading economy.  In Tokyo, total VOCs from fixed sources measured 1.5 million tons in the year 2000.  Backed by law enforcement, the new rules call for a 30 percent reduction by the year 2010.  This 30 percent cut is to be achieved though a unique combination of 10 percent regulatory enforcement and 20 percent voluntary reductions.

The Tokyo Metropolitan Government is taking action to assist small to mid-size businesses by offering measurement and corrective consultation services free of charge.

Comprehensive Pressroom VOC Measurements
Since the printing industry accounts for 22 percent of the total VOC emissions in Tokyo (second only to outdoor painting) it is subject to scrutiny.

	This highly accurate portable instrument was used to take VOC measurements in 60 different locations.

Earlier this year Mr. Katsuaki Terada adviser to the Tokyo Metropolitan Government VOC Reduction Program conducted extensive measurements of VOCs in both waterless and conventional offset pressrooms.  A portable instrument called the Photovac Micro-FID was used to read VOCs throughout two printing companies, Bunshodo and Bunseikaku, both of Tokyo, Japan.

The handheld measuring device enabled dozens of accurate (+/- 0.5 ppm) VOC readings from between printing units to the printer’s entrance lobby.  Everything from rag containers to ink mixing tables were subject to measurement.

At the Bunseikaku plant the investigators had an opportunity to compare readings for waterless printing conducted on the second floor of the building, to those of conventional wet offset printing on the third floor of the same building.  These two separate floors presented a good opportunity to compare VOC emissions from waterless printing to those of conventional.

VOC Measurements Reveal Waterless Advantage

	VOC measurements are taken between printing press color units

The most significant finding was the difference between the waterless pressroom and the conventional wet offset pressrooms located on separate floors of the same building.  When VOCs were measured at each ventilation fan, the waterless pressroom showed 75 percent less VOCs.  To put it another way, the conventional pressroom had four times more VOCs than the waterless one.

Water-washable inks enhance the aterless printing advantage.  Roller washing shows that the VOCs for regular solvent measure over 800 ppm while the water washing solution only measures just over 200 ppm.

There were other measurements that were also a revelation.  Waterless ink totes averaged around 100 ppm VOCs while ink totes for the conventional inks were just under 300 ppm.

Isopropyl alcohol (IPA) was measured in a range of 1,000 to 10,000 while petroleum solvents ranged form 500 to 4,000 ppm, depending on where the measurements were taken.  IPA substitute etching solution VOCs were over an astounding 1,300 ppm.

Crude Oil Price Increases Pressure Printers
Since most of the chemicals used in a pressroom are derived from crude oil, printers can expect higher costs for them.  A large suburban Chicago heatset web printer has already had price increases this year that total more than 20 percent.

The inherent lack of any petroleum-derived dampening chemicals in waterless printing takes some of the pressure off.  Water-washable inks combined with waterless would not only eliminate the use of solvents, but would also result in a huge reduction of VOCs.

So, how much of a barrel of oil goes to the printing industry?  An interesting approximation comes from the U.S. Department of Energy that shows that 18 percent of a single barrel of oil is used for petrochemicals and plastics.  This is the third largest amount behind gasoline at 44 percent and diesel or home heating oil at 20 percent.

All Waterless Printers Can Rejoice
We are extremely grateful for the information supplied by Mr. Terada and for the co-operation of Bunshodo and Bunseikaku in making these comparisons possible.  It proves that waterless printing has a strong environmental advantage over conventional offset.

If offset printers in Japan and Europe want to find a way to exceed mandated emissions reductions, waterless printing is a strong choice when it can reduce VOCs by 75 percent.  It is an advantage that can be heavily promoted.  Of all of our printer members, we would encourage DI printers especially to promote this environmental advantage to their customers.