Flexible packaging printing

This report has been prepared in the context of the UNECE Convention on Long-range Transboundary Air Pollution in 2015-2017. Therefore, it is not focussing on specific regions or industries but providing a general overview of important aspects for the overall sector. We have developed a flexible methodology that can be applied to a broad variety of plants and applications in order to assess the economic and environmental effects of emission abatement measures.

In accordance with the work that is currently conducted by the EIPPC Bureau in Seville we focus on large installations with a solvent consumption of more than 200 t per year.

Industry information has been provided primarily by the industry associations ESIG (European Solvents Industry Group), FPE (Flexible Packaging Europe), FTA Europe (European Flexographic Industry Association) and Intergraf (The European Federation for Print and Digital Communication).

Both primary measures (at the source) and secondary measures are covered (treatment of waste gas with VOCs).

Final report on flexible packaging printing (2017).

Car manufacturing

The study has been carried out in 2015-2016, in order to estimate costs associated with the reduction of VOC emissions from paint shops in the car industry.

To estimate costs of VOC emission reduction, five reference plants have been defined in order to represent all families of paint shops encountered (Solvent Based, Solvent Based / Water Based Mix, Water Based, integrated process).

Three options to reduce VOC emissions for paint shops are considered:

  1. Primary measures corresponding to the reduction of VOC emissions at the source (reduction of solvent consumption or improved collection of solvent),
  2. Secondary measures to treat waste gases containing VOC (end of pipe techniques),
  3. Change for a new paint shop (which enables the use of water based paint systems, advanced paint application systems and waste gas treatment techniques)

For each type of measures, the following parameters are delivered:

  1. VOC emission reduction potentials based on data from plant solvent management plans, modeling and on case studies,
  2. Annual costs based on case studies and modelling,
  3. Cost effectiveness analysis linking VOC emission reduction and annual costs.

To assist the TFTEI technical secretariat to develop the cost estimations for VOC emission reduction from paint shops in the car industry, a working group was set up with representatives of ACEA and 3 car manufacturers (PSA, Renault, Volkswagen).

The study has been carried out with information provided by the working group. Six meetings with industry experts have been organized to exchange information and discuss the approach set up for cost estimation and results.

Final report on car manufacturing (2016)

ERICCa_VOC

The methodology for cost estimation of abatement options for VOCs has been developed for installations in the flexible packaging printing sector and car manufacturing with a solvent input of more than 200 tons per year. However, the design and costs of VOC reduction measures are similar for many other sectors with comparable operating conditions. The tool is therefore expected to be broadly applicable. The methodology provides cost data for primary measures (substitution of products with high solvent content, with some limits (as costs for primary measures are sector and plant specific)) and the secondary measures thermal oxidation and adsorption with solvent recovery. For secondary measures the tool can be used for any type of activities and size of plants (even consumption lower than 200 t/year), independently from primary measures. Costs are estimated for different regulatory objectives based on the solvent management plan methodology or not.

ERICCa_VOC

VOC emission reduction cost calculation methodology

Other activities emitting VOCs

Background documents and associated synopsis sheets were developed by EGTEI from 2003 to 2006 for several activities emitting VOCs.

These documents are provided for information but are now outdated according to TFTEI.

Industrial processes Background documents Synopsis sheet
Chemical industry
Organic chemistry - Steam cracking XLS PDF
Organic chemistry - Production of PVC with the suspension processes PDF PDF
Organic chemistry - Downstream units except PVC production and speciality chemistry XLS PDF
Manufacture or processing of chemical products
Polystyrene processing PDF
XLS
PDF
Solvents Background documents Synopsis sheet
Use of paint in coating of vehicles and refinishing
Coating of cars PDF
XLS
PDF
Vehicle refinishing PDF 1PDF 2
XLS
PDF
Coating of trucks PDF
XLS
PDF
Coating of buses PDF
XLS
PDF
Coating of truck cabins PDF
XLS
PDF
Use of paint in other industry
Coil coating PDF
XLS
PDF
Wood coating (except in domestic appliances) PDF
XLS
PDF
Wire coating PDF PDF
Other use of paints in industry PDF PDF
Other non-industrial use of paints PDF
XLS
Decorative paint
Decorative paint PDF
XLS
PDF
Degreasing / dry cleaning and electronics
Surface cleaning PDF PDF
Dry cleaning PDF
XLS
PDF
Manufacture or processing of chemical products
Rubber processing (tyre production) PDF
XLS
PDF
Chemistry of speciality PDF
XLS
PDF
Paints, glues, inks manufacturing PDF PDF
Leather coating PDF
XLS
PDF
Other use of solvents
Printing industry - Heat set web offset PDF
XLS
PDF
Printing industry - Publication rotogravure PDF
XLS
PDF
Printing industry - Other rotogravure, flexography (packaging, ...) PDF PDF
Vegetal oil extraction PDF PDF
Adhesive application in industry PDF PDF
Adhesive application in building and domestic PDF
Footwear production PDF
XLS
PDF
Wood impregnation PDF
XLS
PDF

Other activities

Background documents and associated synopsis sheets were developed by EGTEI from 2003 to 2006 for several activities.

These documents are provided for information only but are now outdated according to TFTEI.

Industrial processes Background documents Synopsis sheet
Processes in ferrous and non-ferrous industry, and non-metal industry
Cement production PDF
XLS
PDF
Glass production PDF
XLS
PDF