Bound by a Common Goal: Becoming More Green in the Bindery

Businesses throughout virtually all industries worldwide are doing their part to help protect the planet for future generations and preserve resources wherever possible. This article takes a look at some specific ways printers, publishers and print finishing operations can implement “green” initiatives and become more environmentally friendly.

Utilize Energy-efficient Equipment

Perhaps the best starting point in evaluating the green status of a bindery is to take a close look at the machines on the floor. As you would expect, older print finishing equipment does not consume energy as efficiently as new machines. Today’s newest generations of hardcover technologies, perfect binders, saddle stitchers and press delivery systems are engineered not only for the highest speeds and greatest processing efficiencies to increase productivity and boost profit potential for binding operations, they’re also designed to reduce the amount of energy a production plant utilizes.]

For instance, the latest hardcover and perfect binding equipment from Muller Martini is engineered to consume 20-30 percent less energy than other machines on the market while reducing emissions. Energy is actually re-used during the production cycles of these machines. Of course, aside from the environmental advantages, this saves money on energy bills.

Recently introduced saddle stitcher models are also helping to lower environmental impact. Like their hardcover and perfect binding counterparts, the newest stitchers are designed for reduced emissions. Many of these machines have oil-less backing pumps, lessening emissions even more. Some stitchers are equipped with highly advanced air utilization capability as well, featuring single air management devices rather that multiple devices to conserve energy.

Keep Machines Well Maintained

Careful and comprehensive maintenance of binding equipment and mechanisms goes without saying. However, some operators may not realize that in addition to avoiding downtime and adding life to an equipment investment, the right maintenance can also enhance environmental performance. Thorough cleaning is an essential step in keeping all kinds of machines running most efficiently, as is ongoing replacement of worn parts. This is especially important with older machines that can become somewhat looser in their performance and require more energy to turn over. Much like an automobile, a print finishing machine can expect to get more “miles to the gallon” if it is well maintained.

Minimize Waste Throughout the Line

Newer hard- and soft-cover binding equipment, as well as saddle stitching machines, are light years ahead of their predecessors in terms of precision. Automated makeready coupled with state-of-the-art servo technology and other advancements help ensure that the first book off the line is a top quality book, dramatically lowering waste. Furthermore, adjustments can be made on the fly, so machines don’t have to be stopped and re-started again...both reducing waste and saving energy.

Trimmers have also come a long way in the past few years. Trim waste has been diminished to a minimum, and many new trimming machines can segregate waste to maximize recyclable content.

One environmentally conscious strategy: Similar to how you would turn off a light when leaving a room, binding equipment can also be shut off to save energy during extended breaks.

Keep in mind also that decreasing waste and energy usage should not be limited only to hardcover, perfect binding and stitching machines. Press delivery technology plays a pivotal role, particularly with regard to bundling. Today’s high levels of automation assure near-perfect log quality on a very consistent basis. And, when signatures are neatly bundled, as compared to piled loosely, on skids, 20 percent more product volume can be stored in the same amount of space—resulting in less racks, fewer moves by gas-consuming forklifts, and less square footage to heat.

Other Considerations

The proper use of consumables such as stitching wire can also contribute beneficially to the environmental friendliness of a bindery. Some types of wire are engineered so that lighter gauge wire can be used in conjunction with newer stitching head designs. Obviously, this reduces the amount of wire material needed. What’s more, it can lower shipping costs by making products lighter.

Also essential to consider is whether or not your stitching wire is lead compliant. The U.S. Consumer Product Safety Commission has issued new requirements for lead content, effective Feb. 10. Check with your stitching wire provider to make certain the wire you’re using is compliant.

Another environmental consideration is the quality of ambient air in a binding facility. Earlier in this article, we mentioned the importance of reduced machine emissions. Also key is the exposure of personnel to production materials. The latest hardcover and perfect binding machines have insulated glue reservoirs. Also, a number of new adhesive binders, for example those using a PUR extrusion system, have closed glue pots to help prevent excessive exposure to the surrounding atmosphere.

Yet another environmentally conscious strategy might be the most obvious one of all: Similar to how you would turn off a light when leaving a room, binding equipment can also be shut off to save energy during extended breaks. The latest hardcover equipment and perfect binding technologies include timer circuits to monitor incoming air. If the line is down for a prescribed amount of time, the air will automatically shut off. Energy can also be conserved on saddle stitchers. Let’s say you’re not running a pocket...simply turn off the valve, which in turn will stop the pump from over-running needlessly.

As with any socially responsible business, green initiatives should be a prominent part of the business plan at a binding operation. When evaluating an equipment purchase, remember to ask the equipment supplier for energy usage and air usage calculations. Compare these calculations among different suppliers to be sure the machines you’re contemplating purchasing are as efficient as possible. Also ask your supplier to assist you in spotting inefficiencies throughout your facility and for ideas about improving processes.

Jim Kaeli is the division manager, Book and Publication Binding, and Doug Stryker is the division manager, Print Finishing Systems, at Muller Martini.