Maple-Vail Low VOC Trial
By Graphic Arts Online Staff -- Graphic Arts Online, June 11, 2008
York, Pa. (June 10, 2008)…The Maple-Vail Book Manufacturing Group and Amerikal Products Corporation, two of the printing industry’s most progressive and entrepreneurial companies, have joined forces to make history by pioneering a process that will allow books to be printed on a heat-set web press without any curing devices, ovens or blowers. The new sustainable process will revolutionize how books are printed and manufactured.
The first book to be printed using the THINKTech™ process will be The Dismal Science, by Stephen Marglin, a senior professor in the Economics Department at Harvard University. Published by Harvard University Press, this book will debut this new process on June 18 at Maple-Vail’s York, Pa. facility.
“Everyone has their version of being green,” said Steve Brooks, prep/press superintendent at Maple-Vail. “But this goes completely beyond the typical ways to be more eco-conscious. This process will forever change how books are printed. It will allow printers to reduce their energy costs and VOCs while increasing quality.”
The new process, which utilizes Amerikal’s Thin Ink Film Technology™, was developed after Maple-Vail switched from traditional pressroom chemistry to Amerikal’s line of sustainable chemistry called Genesis®.
According to Brooks, Maple-Vail started running Amerikal’s blanket washes, roller washes and fountain solutions on their sheetfed presses last May. After experiencing tremendous results on the sheetfeds, Maple-Vail and Amerikal tested the THINKTech™ Thin Ink Film Technology™ process on a heat-set web press. After considerable research and development, they realized it could be duplicated and perfected to achieve even more impressive results.
The new process will be accomplished by:
• Turning off gas-fired ovens, chill drums, chill water compressors, electrical pumps, silicone applicators and electrically powered blowers
• Replacing traditional press cleaners and wash-up chemicals with Genesis® BRIGL Wash
• Building inks to run with THINKTech™ Thin Ink Film Technology™ standards
“We are constantly striving for new ways to improve the printing and manufacturing process,” said Bob Danielson, president of Amerikal. “What we’ve created with Maple-Vail is a prime example of how we’re committed to helping our customers achieve great results. We not only helped them reduce their carbon footprint, we also reduced their overall costs and improved productivity and that is imperative in today’s economy.”
By implementing this technology, Maple-Vail will experience the following results on their web presses:
• Complete elimination of natural gas usage for the ovens
• Dramatic reduction in electricity since the chillers are no longer necessary
• VOC ink levels slashed from 31-42 percent to just under 3 percent due to the fact the THINKTech™ process is bio-based
• VOC emissions from the special fountain solution and blanket wash result in a reduction to a mere fraction of the prior levels
• Increased production efficiency because of the quick-drying nature of the THINKTech™ process
• Elimination of all federal and state regulated toxins such as silicone, federal 313 chemicals and Hazardous Air Pollutants (HAPs)
One additional benefit is that the THINKTech™ process will expedite the drying process while improving quality. The throughput to the bindery will be cut from days and hours to just minutes. This new method of printing books results in non-wavy books that are odor-free and safer for the environment and consumers.
“It’s important to note that this new process wouldn’t be possible if any piece of the puzzle was missing,” said Danielson. “We designed and engineered this process to meet Maple-Vail’s goals and objectives and each component is necessary to ensure sustainable printing occurs.”
The first sustainable book will be printed at Maple-Vail’s facility in York, Pa. on Wednesday, June 18.
About Maple-Vail
Maple-Vail provides complete book manufacturing and distribution services to a wide range of book publishers. Manufacturing locations in York, Pa. and Binghamton, N.Y. are capable of manufacturing hardcover and papercover books in a wide range of trim sizes, bind styles, and run lengths. Complete distribution services are provided from three locations in Central Pennsylvania. For more information regarding Maple-Vail’s services, please contact Bill Long, vice president of sales and marketing at long@maple-vail.com, or visit the company web site at www.maple-vail.com.
About Amerikal Products Corporation
Since 1989, Amerikal Products Corporation has been committed to designing and engineering process management equipment to reduce costs and improve productivity in pressrooms worldwide. The company also offers printers a full line of sustainable pressroom solutions called Genesis®. Amerikal’s comprehensive approach to training and implementation helps printers reduce waste, pollution, energy costs and eliminate hazardous chemicals from their facilities. To learn more about Amerikal, please visit www.amerikal.com
About Maple-Vail
Maple-Vail provides complete book manufacturing and distribution services to a wide range of book publishers. Manufacturing locations in York, Pa. and Binghamton, N.Y. are capable of manufacturing hardcover and papercover books in a wide range of trim sizes, bind styles, and run lengths. Complete distribution services are provided from three locations in Central Pennsylvania. For more information regarding Maple-Vail’s services, please contact Bill Long, vice president of sales and marketing at long@maple-vail.com, or visit the company web site at www.maple-vail.com .
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