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PAC Award Winner-Silver

Jones Packaging Inc.

Overview

Jones Packaging Inc. is a world-class provider of premier packaging with innovative sustainable solutions. In furtherance of its core value of environmentally responsibility, Jones created Greensweep, a business to business sustainability tool which focuses on sustainable business processes and packaging design, the use of eco-certified and sustainable materials, as well as the education and marketing of environmentally responsible packaging options to customers and consumers.

Greensweep focuses on Jones’ own internal processes as well as those of its customers. Internal areas include the use of management systems, clean production practices and more efficient equipment such as:

• 12 recycling and recovery programs

• elimination of solvents and films

• reduction of water consumption

• reduction of waste inks and sheets

• installation of energy efficient equipment

• VOC free printing

• Improved carton designs reducing size

• sourcing eco-certified materials

• certification by sustainable forrestry organizations

• reduction of pallets and transportation

• use of eco-logos to highlight to customers and consumers sustainable practices and materials.

Motivation for Change

Each year, Jones Packaging reviews, sets and measures its targets and performance in terms of its Environmental Management Standard (EMS) under ISO 14001. This includes:

• Provision of a framework for using pollution prevention practices to meet EMS objectives

• Increased efficiency and potential cost savings when managing environmental obligations

• Promoting predictability and consistency in managing environmental obligations

• More effective targeting of scarce environmental management resources

• Enhancing the company’s public position with outside stakeholders.

Cost Effectiveness

Less heat is emitted from the fluorescent bulbs - which had an impact on air conditioning usage and costs in the summer. Energy consumption was reduced and savings of approximately $400 per month were achieved

Sourcing

• Certification by FSC, SFI, PEFC, PAC-SECURE and the publication of marketing materials, presentations and website links relating to these.

Clean Production

• A Cyrel Plate Processor was commissioned which eliminates the need for solvents for printing plates

• A ESKO CDI plate imager and Suprasetter for offset CTP was purchased which eliminates the need for and use of film

• A ‘Proofless Process’ has been implemented which results in the use of less paper, no physical transportation of proofs

• A transition to catalyzed water based white ink on shrink sleeves has resulted in a reduction of solvents used

• A New Komori Press has been purchased which uses less inks, less cleaning fluids and rags, reduces industrial waste, reduces waste sheets, is more energy efficient, can print VOC free UV inks and is manufactured in a factory which only uses solar and wind power

Effective Recovery

• Solvent Recovery Program. A solvent recovery machine was set up in the chemical room to recycle blanket washes from the litho presses

• Corrugated Cardboard Recycling Program. All corrugated cardboard is collected and sent for recycling

• Plastic Wrap Recycling Program. All shrink plastic wrap is collected and sent out for recycling

• Aqua Solv Recycling Program. A filtration system was set up to recycle Aqua Solv and water for reuse

• Source Separation Container Program. Bins have been distributed throughout the plant to ensure recyclables are not discarded with regular garbage, thereby increasing recycling rates

• Office Paper Recycling Program. Collection is done at each cubicle and throughout the plant to ensure all white paper is recycled

• Paper Re-use Program. Bins have been distributed throughout the office areas to collect one-sided paper to be re-used in printers and copiers

• Aerosol Can Program. This program has been set up to eliminate aerosol cans as HAZ waste and to make them recyclable metal

• Alkaline Battery Recycling Program. A recycling program was introduced to reduce the toxic waste of batteries being discarded with general waste

• Litho Printing Plates Recycling Program. All litho printing plates used on the presses are sent for recycling

• Skid Recycling Program. Old skids are sent for recycling reducing the amount of wood sent to landfill.

• Paperboard Scrap and Trim Recycling Program. All virgin and recycled box-board scrap and trim arising from the manufacture of folding cartons is collected, baled and sent back to the supplier mills for recycling.

Community Benefit

Holding a SUSTAINABILITY CONFERENCE on 25 October 2007 to educate all of Jones Packaging’s customers on sustainability

• A Sustainable Packaging Toolkit to assist designers, manufacturers and customers in their sustainable efforts in regard to packaging and the environment

• Tours have been provided for over a 100 interested companies to showcase the lighting retrofit project and to educate them on the benefits of thereof.

Material Health

• The Komori press can print VOC free UV inks

Resource & Energy Optimization

ENERGY One of the goals for Jones Packaging’s ISO 14001 EMS for 2007, was to reduce energy consumption by 5%. A detailed energy audit was conducted for the London facility and it outlined that 30% of the energy consumption was from lighting. By retro-fitting all the lighting for the London facility, energy consumption would be reduced and thereby also reducing a key component in greenhouse gas production. In addition, to the environmental benefits, Jones Packaging, would also reap the economic benefits of energy cost savings. The project was implemented in January 2007 and had the following impact:

700,000 kWh saved from January 2007 to December 2007

Fluorescent lighting is 50% more energy efficient than metal halide lighting

The new lighting system has longer rated lamp life compared to metal halide and there is less replacement of bulbs and therefore less waste disposal

The total energy consumption from lighting has decreased by 15.75%

The warehouse in London was sectioned off into three areas and motion sensors installed in the three areas, so that the lighting turns off in each area when no motion is detected, thereby allowing work to continue in certain parts of the warehouse, but reducing energy consumption in the unoccupied areas.

A humidification system was installed whereby a boiler was eliminated and pressurized water used in its place, thereby conserving energy

• A motion sensor was installed in the print and photocopy room to reduce electricity while the room is unoccupied. c) WATER Jones Packaging has under taken a number of steps to reduce its water consumption.

Categories: PAC Award Winner Machinery Facility/Process

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