How Green Grew Sales
We first pushed customers to be green-minded. Now, it's why they print with us.
By Christina Faller, Offset Impressions -- Graphic Arts Online, February 1, 2009
Even before green was vogue, George Ruth, president of Offset Impressions, believed in doing the right thing. He was aware of the toll that the printing industry could have on the environment, so he looked for ways our company could make a positive impact. "Printers inherently use more paper than probably any other industry. I feel that we have a big responsibility to make changes where we can," says Ruth.
Offset Impressions has two facilities spanning 74,000 sq.ft. in our Reading, PA campus. Founded in 1976, we now operate three-shifts. Our expert team collaborates with customers to develop innovative solutions to their unique needs, handling the details, right through to the OI Advantage for mail fulfillment and distribution. In managing the art, science and fine detail of color printing, Offset Impressions exercises an environmental commitment through our use of paper, print-on-demand solutions and sustainable lean manufacturing.
Our first monumental change happened in January 2006, when we were certified by the Forest Stewardship Council (FSC). Offset Impressions was the third company in the state of Pennsylvania to become certified by the FSC.
"It was important to formalize our commitment to making environmentally responsible choices," Ruth says. With an FSC certification and strict regulations for FSC logo usage, printers can ensure that all paper and paper products have come from responsibly managed forests. On certain paper stocks, we are even able to calculate and publish the net environmental impact. Other smart practices have followed our FSC certification, as we install new equipment, implement new processes and products, and encourage our customers and employees to make changes where they can.
One of the more noteworthy installations was a FloClear water filtration system on our two 40" presses. 
Designed for continuous water balance on the presses, the system re-circulates the fountain solution through a multi-state filtration system that separates and removes contaminants. The FloClear system allows the presses to use the same water and fountain solution for eight months, as opposed to the standard two weeks. The fountain solution keeps the chemistry fresh, which makes for both a consistently higher quality printing product and a sustainable process.
Reducing chemistry usage
Through our unique "direct to plate" developing system, Offset Impressions significantly reduces the amount of processing chemicals it needs. "We added a turning device that runs the plates through a narrower processor than even the manufacturer had intended," say Ruth. Because the plates fit through a smaller space, it takes about 25% less developing chemistry. Plate processing chemicals are also mixed with a neutralizing agent before disposal.
A paperless workflow may seem ironic for a printer, yet 85% of traditional print files are received via FTP file transmission. Other client management tools such as digital printing, web-to-print, and soft proofing have helped reduce print copies and proofs. But using paper is inevitable in our industry, so Offset Impressions recycles—about 445 tons of paper and corrugated in 2008
Beyond paper, recycling programs include inks and oils, shop rags and aluminum press plates. Offset Impressions has used vegetable-based inks—including soy inks—for years. Each week, we have an environmental group pick up all of the used and leftover inks to properly dispose of them. The shop rags are sent to an industrial cleaning service to be properly cleaned and sent back to Offset Impressions to be reused. All of the recycled press room oil is donated to a local small business that uses it for furnace fuel.
In the last few years, sustainability has come a long way. When Offset Impressions committed to green initiatives, the paper cost was higher. Now the number of available FSC-certified paper stocks has increased due to customer demand. "Initially, we had to try to influence our customers to be green-minded," says sales VP Jim Federico. "Now, there are a number of companies who will work with us because we practice sustainable manufacturing." Wal-Mart, for instance, asked us to use paper with the FSC seal for its Brand Book, later awarded by Mohawk Papers for excellence.
FSC, lean manufacturing and green printing processes are especially important to manufacturers who make necessary products that, by definition, are not good for the environment. "We encourage [them] to make changes where they can," says Frederico. "Using printers that practice sustainable green printing is one simple way they can show consumers they are trying to operate responsibly." Offset Impressions is already looking for ways to advance our green initiatives—from certifications to adopting new technologies. We constantly investigate emerging technologies to stay current and offer customers the latest advantages. In the meantime, we keep staff trained on sustainable best practices and educate printing consumers on the advantages of green operations.
Online
graphicartsonline.com/sustainability
