1. Introduction to Energy Efficiency

Energy efficiency is defined as obtaining the same level of output while using less energy input. Achieving these goals would enable an industrial company to save substantial utility costs. Engaging in energy efficiency not only helps reduce utility costs, but also creates environmental benefits such as reduction of carbon emission that contributes to global warming. For certain type of companies, implementation of energy efficiency is not only an option, but a necessity. This is especially, in countries like UK, where government has regulated utility usage by sectors. Utility companies in the printing sector have to comply with Low Carbon Energy Audit requirement. Therefore, future audit has to be conducted and submitted to UK audit department before 30th June 2013. Upgrading inefficient equipment to energy efficient ones is the most effective method to reduce utility usage.

The case company is one of the biggest in the printing industry in UK. Printing companies require printing machine, cutting machine, and laser machine to complete daily tasks. These machines consume a huge amount of utility, making printing companies the sector with the second largest utility usage. The high consumption threatens the profit margin of a company, as the utility bill is an essential part of business operating costs. It is crucial to reduce the wastage level of printing companies. These two factors create great motivation for the company to implement energy efficiency and try the best to reduce utility consumption at the root causes. Even a slight reduction in utility consumption can lead to significant real financial savings.

2. The Printing Industry's Energy Consumption

The printing industry is a large consumer of energy. Printing activities are demanding in terms of the energy consumed for the operation of equipment and machinery, and the heating, cooling, and lighting of their premises. Researches on energy-efficient methods in this sector have attempted to tackle different aspects of the case. One study monitored and analysed the energy consumption of printing facilities and explored the use of alternative renewable energy sources such as photovoltaic solar cells and wind turbines. Another examined the development and implementation of a smart metering system and an energy reporting system for printing companies. Lines of action for the creation of an awareness culture were also investigated through training courses.

Energy wastage is a serious problem for the printing industry because most of the equipment used is old and tending to consume large amounts of energy. Exploring the renovation of the existing print-works in terms of equipment and machinery investment, along with energy-efficient methods, can considerably cut down wastage of resources and thereby reduce planetary pollution. A case study of a UK printing company analysed the important aspects that affect printing companies in the UK in terms of energy consumption and looked for effective energy-efficient development plans to make the company as energy-efficient as possible. It also assessed the financial benefits of such plans and the progress of energy-saving methods in the UK in the last few years.

3. Identifying Energy Wastage

Energy efficiency involves using less energy to perform the same task, thereby eliminating energy wastage. Globally, the Royal Academy of Engineering estimates that approximately 32% of consumed energy is wasted. The printing industry is notably energy intensive, with United Kingdom regulations imposing strict standards on usage. The simplest yet often neglected measure—switching off idle office lights and devices—remains one of the most effective energy-saving actions.

Assessing patterns of energy use is a critical first step toward reducing demand. Typical energy usage graphs for the printing industry generally reveal that significant energy is wasted during working hours. An audit conducted in a UK printing company revealed that the existing hour-by-hour energy use, combined with office culture, led to substantial wastage and elevated running costs. Through the adoption of energy-saving measures and a concerted effort to reduce consumption, the company achieved an overall demand reduction of 18%. The transformation required overcoming employee resistance and addressing technical limitations associated with the equipment. These challenges were managed by instilling an energy-conscious culture and installing more efficient hardware.

3.1. Common Sources of Energy Loss

In the printing sector, energy efficiency is an area often less understood or regarded as onerous to achieve. The low costs of energy and the relatively small consumption of individuals and businesses have encouraged a culture of energy wastage. The antiquated equipment used in many printing factories wastes large amounts of energy. A UK printing company recognized its inefficient production procedures and the potential for waste of resources and money. As a result, the firm sought ways to reduce energy consumption. Since energy consumption represents a significant cost for the company, any reduction translates directly into real financial savings. The process of change involved both investment in energy-efficient machinery and creation of a culture of energy awareness among the workforce.

The company began by measuring the baseline consumption of lighting, printing machines, and other areas. These figures were then converted into financial costs to provide an overview of the impact on the business. Next, staff members were engaged to raise awareness and encourage reporting of unnecessary energy use. Energy consumption targets were established, and strategies to exceed them were developed. Energy-efficient machinery was procured, installations such as solar panels and wind turbines were considered, smart metering was implemented, and staff received targeted training. A formal energy management and reporting procedure was put in place to monitor achievement against targets. Initial focus centered on defining acceptable consumption standards for assistants working in the print room.

3.2. Impact of Inefficient Equipment

Energy efficiency measures are essential to stop unnecessary energy losses and are equally important for the environment and business profitability. Energy is wasted when inefficient equipment is used, when the correct equipment is used but the process flow is suboptimal, and when the equipment is running on energy-intensive modes. These points are emphasized through a real example of a UK printing company that reduced its energy consumption by over 15% despite having a relatively energy-efficient production process. The approach involved building an energy-efficient company that takes every possible step to reduce energy losses. Although such an approach is applicable to all industries, the financial savings are specific to the UK context.

The example demonstrates that upgrades and energy efficiency may hold the key to energy savings. Even in industries with relatively energy-efficient machinery and processes, companies can aspire to save energy further by changing their organizational mindset. The printing company’s maintenance team followed a cogent process to achieve real financial savings by transforming the management of the business. In addition, training employees in energy efficiency, generating on-site solar and wind energy, and monitoring and reporting energy use help to build a culture of energy mindfulness. Organizations should consider these steps before using a new process or machinery because the benefits can be considerable. These apparent common-sense steps often face resistance, which can be managed through good leadership and training.

4. Case Study Overview

Energy efficiency means using less energy for a task, producing the same result with less energy, or eliminating wasteful actions. In industry, it�s about changing to energy-efficient processes and equipment, eliminating waste in operations, and becoming more energy-conscious. A UK printing company that installs printing cylinders for its customers has learned how its employees can be central to improving energy efficiency and how investment and an energy-conscious culture can cut costs and carbon emissions.

Printed products occupy an important place in daily life and in the economy. Although print consumes considerable resources, it is possible to make products more resource and energy efficient through changes at the product-design stage. Nonetheless, printing uses a lot of energy, most of it from coal- or natural-gas-fired power stations. Time wasted working on inefficient machines also scrapes the budget for extra energy. Energy-efficient design can result in reduced emissions of carbon dioxide. Using renewable sources of energy is another way to reduce emissions. For example, electricity from photovoltaic and wind-power plants produces no emissions at the point of generation. However, smart metering alone is not enough; regularly reporting and specifically addressing energy consumption in companies raises awareness and can lead to savings.

5. Implementing Change: Initial Steps

The journey begins with a thorough investigation of present equipment and energy use, including a usage audit and identification of jaundice points. This information supports setting a clear energy reduction goal and helps pinpoint where to make quantifiable savings. Once the data are in place, other areas that hamper achieving the goal should be identified. In addition to wastage, inefficient equipment is also a major cause. It is not necessary to scrap such devices immediately; viable alternatives exist, such as retrofitting. Employee training forms another fundamental part of the overall strategy.

Changes will probably be resisted increasingly by employees in the short term because they involve additional work. Resistance can be overcome, and a gradual change of culture fashioned through effective incentives and much patient persuasion. Raising awareness of the environmental impact usually helps, especially training regarding energy-efficient use of equipment of all kinds, including telephones, computers, photocopiers, printers, and fax machines. Real financial savings are generally best demonstrated by health and safety staff or trade union representatives. Taking account of employee considerations is crucial, lest management be seen simply as concerned with saving money by any means.

5.1. Conducting an Energy Audit

Energy efficiency is a widely misunderstood term. If a particular process is described as being more energy-efficient, or less efficient in its use of energy, it generally means that more or less end-use energy is required. For example, a type of machine or operating process that uses less energy for a given unit of output is said to be more energy efficient. However, such a definition is not complete, because the quality, quantity and cost of the end-use energy must also be considered. Energy efficiency is therefore a relative concept, and the amount of energy embedded in a product is only one possible measure.

Energy wastage takes place when inefficient equipment uses more energy than newer, properly maintained and more efficient equipment. It can also occur through inappropriate or unnecessary operation of machinery. Energy savings on industrial sites can be achieved through improvements to existing equipment and plant, purchasing energy-efficient machinery, regularly maintained equipment, and adopting a good organizational approach to the use of energy.

5.2. Setting Energy Reduction Goals

Energy efficiency means using less energy to provide the same level of energy service. It is a key component in manufacturing competitiveness, improving profitability by reducing energy bills, and in environmental management by decreasing emissions of greenhouse gases and other pollutants. The printing industry can benefit from upgrading to energy efficient technology and ironing out wastage. Like most industrial sectors, the printing industry is a significant consumer of energy. Energy savings are achievable by installation of appropriate instrumentation and equipment design, revisions to operational procedures, training employees to take a more active approach to energy management and by reviewing sourcing of energy. Energy wastage is evident in many print sites in the United Kingdom, often linked to poor specification and design of equipment; equipment run in an inefficient manner that is not conducive to minimum consumption; inefficient equipment in comparison with new equipment; and indirect usage of energy such as compressed air, air conditioning and heating. Reconciling the potentially conflicting variables of resource consumption, environmental impact, fossil fuel depletion, waste processing, and financial saving is a complex undertaking for any manufacturing company. Sacrificing the bottom line to achieve an energy target is not a desired option, yet the use of fossil fuels for energy is at once finite, environmentally destructive, and costly. A practical solution that will meet these conflicting targets is required.

Energy savings are achievable in many manufacturing sectors by integrating appropriate instrumentation and design with simple management procedures and employee involvement. In the UK, energy wastage is evident in many printing sites, often linked to poor specification and design of equipment, inefficient practices, reversion to using older equipment for cost reasons, and indirect usage of energy in compressed air, air conditioning and heating. A case study company, a UK printing firm, set an initial target of achieving a 20% reduction in energy use in its Chester facility. After careful analysis of the potential savings, the eventual aim was revised to a 15% saving. A practical solution that reconciles the conflicting variables of resource consumption, environmental impact, fossil fuel depletion, waste processing and financial saving was developed. The solution integrates simple management procedures, employee involvement, data monitoring, and investment in new technology. Once implemented, it was anticipated that the savings target would be maintained and improved upon. Setting energy reduction targets demands recognition and understanding of all the elements that limit impracticable and potentially costly decisions. Creating a culture whereby energy reduction or a decreased environmental impact is accepted as a category in competition with apparent delivery may require careful handling, as may ensuring that operators are specifically trained for efficient operation of their equipment.

6. Upgrading Equipment

Equipment in the printing process is responsible for much of the industry’s demand. Upgrading these machines or retrofitting pieces of equipment with more energy-efficient technologies is a logical next step for changing practices and improving energy efficiency. New machines might be more energy efficient, but it remains important to understand basic energy facts, such as whether the majority of electricity use occurs when machines are in operation or on standby mode. Bringing smart meters into the workplace can help companies identify which devices, areas and times are high users of energy.

A small UK printing company found that the biggest energy wastage occurred in their drying processes. By introducing new dryers with heat recovery and energy efficiency systems, the company also made use of solar panels and a small wind turbine to generate part of its own energy supply. Although the start-up costs were high, the long-term financial gains were clear. Creating a culture focused on energy awareness also helped minimise wastage. The application of UK regulations and the business cost of not introducing energy-efficient measures motivated the company to train staff in energy-efficiency methods at both the production and management levels. Through regular reporting of electricity consumption, energy targets were set and achieved. The company achieved savings of over £4000 in just over a year, and these reduced costs had a real impact on the organisation.

6.1. Investing in Energy-Efficient Machinery

The printing sector’s energy demand is considerable and, in many organisations, a large proportion of that energy is wasted through the use of poor or inefficient machinery and through a lack of control measures. Investing in energy-efficient equipment therefore offers a major opportunity to reduce energy bills and minimise carbon emissions. Starting with the simplest steps — such as fitting a timer that switches equipment off over the weekend — can make the energy savings add up. It is also vital to purchase energy-efficient machinery for new or replacement equipment.

Establishing an up-to-date understanding of how energy is used in the business provides a starting point. By monitoring consumption over time and reporting it in an accessible way, energy use becomes part of staff discussion and decision-making and a culture of energy efficiency is established. Employees should be encouraged to put forward ideas and be given the relevant training and information, as well as clear targets and responsibilities. Expansion of the company’s energy mix to include carbon-free sources, such as solar power and wind turbines, is a further step.

6.2. Retrofitting Existing Equipment

Energy efficiency manifests when energy supplied to a system exceeds the output energy actually required by the system’s processes. Optimal efficiency equates energy supplied to energy required: Energy Efficiency = Energy output required Energy input required > Energy Efficiency > 1 In real-world contexts, efforts aim essentially at reducing the difference between input energy and required output energy, since the latter cannot be altered. Particularly in the commercial printing industry, energy consumption changes by only ±15% despite considerable process throughput variation; accordingly, reductions are achievable solely by reducing the basic power demand of the processes.

The printing industry, primarily due to its inherent process nature, demands a substantial and constant energy supply. Consequently, a significant amount of this energy is wasted; sources encompass the required but unused portions in the process itself, leakage through poorly insulated machines, inefficient equipment, and utilising more expensive energy sources. Resources consumed are not only electrical energy but also materials such as water and solvents, which adversely affect the environment. In response, a UK printing company initiated a programme to reduce energy wastage, aiming to justify an investment in energy efficiency by generating real money savings. Although requiring an initial financial outlay, the resultant reduction in electricity costs would soon generate ongoing revenue. Besides the actual investment, changes in behaviour were also necessary. Key determinants for success location included site conditions, process route, technology, specified utilitiy level, perceptions and culture; recommendations encompassed employee engagement, management support, awareness, controls and assessment. The toner toner-fusing printing process demands a much higher level of energy supply than other parts of the process. Although it remains physically possible to reduce the energy demand by process route optimisation at the toner-fusing stage, printing press control systems both physically and legally limit such changes.

7. Employee Engagement and Training

Technical limitations frequently present a substantial barrier to energy efficiency in UK printing companies. Even straightforward actions, such as switching off electrical equipment when it is not required, are hampered by poor-quality equipment. If lighting is provided by short-life fluorescent tubes or metal halide bulbs that each have a high start-up energy demand, it is not cost effective to implement these simple steps. More widespread changes to incorporate new technology that demands less energy, such as new systems for pre-press and printing, will inevitably cause some disruption during the implementation phase, and the lasting changes required such as altering temperature settings of plate rollers will alter the work pattern.

Such technical impediments can be overcome provided there is energy awareness amongst the workforce. Creating a culture of energy efficiency, achieved through specific training, is perhaps the most critical factor in overcoming resistance to change in the print industry. Investing in energy-efficiency training for printing staff often results in tangible financial savings, especially in areas that can be improved without new equipment, such as behaviour change either at work or at home.

7.1. Creating an Energy-Conscious Culture

Energy efficiency involves eliminating energy waste and should never compromise the quality of a service or product. Its significance extends into global matters and everyday industrial business operations. The printing industry consumes considerable energy; for example, a typical commercial printing company in the UK employs approximately 50 people, produces about 5 million A4 sheets per week, and uses roughly 130,000 kWh of energy. Much of this demand is unnecessary because the company pays for power lost to the atmosphere, or that which serves no useful purpose.

Making a business more energy efficient requires time, effort, and, in many cases, money. Spending money on reducing energy consumption will deliver future savings and the length of time needed to recoup that expenditure is certainly something to consider. For companies subject to the Carbon Reduction Commitment Energy Efficiency Scheme, any money spent to reduce energy usage (and improve the energy efficiency of the business) could have a significant impact on taxes and the associated financial penalties. The improvements need not come from new and innovative machines; in fact, much can be achieved by addressing the efficiency of the only factor that can make or break a company—its employees. Instilling a culture of energy awareness and responsibility can produce more immediate savings than the use of fancy metering devices or the installation of solar panels.

7.2. Training Programs for Staff

Energy efficiency is about providing the same level of service for less energy input. In industry, this principle involves using technical means to reduce energy demand. For example, a large UK printing company consumes substantial energy for printing and cooling. Energy wastage was identified—primarily stemmed from employees' lack of energy awareness. Backed by management support, a training session introduced the problems of excessive energy consumption, CO2 emissions, and the financial waste linked to unnecessary energy use by inefficient equipment.

Energy efficiency aims for minimal emissions while achieving maximum energy utilization. Key approaches include implementing new equipment with superior energy performance, retrofitting original equipment, accommodating higher energy demand using renewable sources such as solar and wind power, and promoting the efficient use of existing equipment. In addition, establishing an energy-saving culture involves creating teams, providing training, implementing routine reporting, monitoring energy usage, and enforcing related regulations. All these measures contribute to reducing the printing company's carbon footprint. Despite being costly and time-consuming, they are indispensable. Many UK printing companies have yet to adopt similar measures because of their technical limitations.

8. Utilizing Renewable Energy Sources

Energy efficiency is the use of technological means to reduce the quantity of energy required to provide products and services. Efficient energy use showcases the possibility of delivering greater value with less energy input. Energy efficiency in the printing industry describes the adjustment of the printing processes in accordance with the energy use and consumption of the industry. A major part of wasted energy is caused by the slow adoption of new technology. The industry uses a great deal of electrical and thermal energy and this may derive from coal-based power stations that produce large quantities of carbon dioxide and other pollutants.

A UK printing company is well on its way in reducing energy consumption and deriving greater environmental sustainability. The company has shown that considerable savings are achievable in the real financial world by systematically measuring and challenging energy usage within the business. The drive towards more energy-efficient design has revealed that a combination of stringent UK regulations and legislation, high energy costs, and a wish for greater environmental sustainability have contributed to a culture of understanding and commitment within the energy-conscious business environment.

8.1. Solar Power Integration

Energy efficiency is a concept well known in developed countries and these countries have already implemented or are in the process of implementing very ambitious strategies to reduce energy usage and costs. The printing industry is one of the main industries, not only because of its high-energy consumption, but also because it relies on high-speed logistics—which typically use transforming equipment that runs at full power, regardless of the real demand—to carry out its operations. Together, these factors give rise to considerable energy wastage. The solutions are not particularly difficult to implement; they involve: Upgrading equipment and printing machines in order to enhance their energy efficiency.

Because of the company’s previous energy audit, the printing firm knew where it was wasting energy and had a clear idea of where it needed to make changes. In addition, the company was aware that a new, energy-efficient facility, designed in accordance with the guidance provided by the Spanish Technical Building Code, would be constructed in the near future, so it implemented the suggested cost- and energy-saving measures in the existing printing buildings using the skills of its own personnel. These measures ensured that energy was efficiently used, that the employees were well informed of the relevant issues and that all modifications were in line with the above regulations. Moreover, it is important to emphasize the real financial savings made by the company.

8.2. Wind Energy Opportunities

Wind energy is a relatively promising energy source within the printing sector and can be used in conjunction with conventional energy. The electricity generated during windy periods enables the operation of the imprinter's machines and lighting systems and is used to pump the washing liquid to work together with solar energy.

The imprinter is equipped with a small three-phase generator, designed to operate at 400 V and an interface voltage frequency of 50 Hz. Initially, it is possible to supply its activity only with electricity generated by the wind energy system and to sell the excess electricity through the public distribution network associated with the system.

9. Monitoring and Reporting Energy Usage

Implementing smart metering and online monitoring immediately reduced consumption by more than 10 per cent in a UK printing company concentration. Within printing companies, energy management is important for both economic and environmental reasons. Although printers are typically highly energy intensive, few organisations fully understand the scale of possible energy reduction, and where best to make energy savings. An energy audit at the UK firm identified areas where improvements could be made, and new targets for costs and emissions were set.

Identifying sources of wastage is critical in reducing energy consumption, as many areas could benefit from change: a print room can be lit poorly, for example, while equipment in the finishing section – guillotines, sheeters, or perforators machines – may be very inefficient. Many companies now have automatic power down or sleep mode on all newer machines, and older equipment can often be retrofitted with a PowerMaster system that shuts down idle machines. Creating a culture of awareness among employees is also important, not simply the buying of efficient equipment.

9.1. Implementing Smart Metering

A principal strategy for decreasing energy wastage is the installation of smart meters. These devices monitor energy consumption in real time and generate usage reports. Companies that still use analogue meters can implement smart metering through various methods, permitting detailed analysis of electricity use on an hourly or even sub-minute basis. These methods require the installation of monitoring devices alongside the existing meters and are typically more cost-effective than replacing the meters themselves.

The benefits of smart meter output have been demonstrated in the case of a UK printing company, which began focusing on reducing electricity consumption in 2012. The company’s printers and associated equipment were identified as major areas of wastage. The focus was therefore on intercepting dedicated waste, including energy lost through inefficient technology, complex automated processes, and poor maintenance. Changing cultural behaviour also played an important role in reducing the bill. Energy costs had previously been considered solely as an overhead, thereby hindering improvement efforts, and employee awareness had to be deliberately raised in order to promote good practice during working hours.

9.2. Regular Energy Reporting Practices

As energy costs rise, companies consider upgrading to more energy-efficient equipment to reduce energy demand and achieve corresponding cost reductions. While investment is significant, operations that are energy efficient gain long-term advantage and resist rising prices. Mechanical removal of waste energy—for example, through enhanced building insulation and double glazing—reduces energy usage, as do the installation of solar panels and wind turbines. In addition, making changes to employees’ working practices, raising staff awareness of potential energy wastage, and providing specific energy training can yield dramatic reductions in electricity consumption throughout industry.

Printing is an industry with particularly high power consumption, especially in the UK, where electrical power has a particularly high cost. Many printing companies therefore examine ways to reduce energy consumption and improve overall carbon footprint—thereby lowering electricity bills. A case-study company in the UK illustrative of the wider printing industry was successful in making substantial savings in electricity usage. Some savings resulted from staff changing working practises, other changes came from improvements in the systems employed to control the power consumed by the printing machines, several required investment in more energy-efficient equipment, and for some, the direction was reversed. Although some of the changes made in reducing the usage of electrical energy were required to upgrade older equipment, the driving force was the overall financial benefit. The introduction of smart meters and the ability to review the power consumption of the company on a daily, weekly and monthly basis created the culture necessary for the staff to work together to achieve this. These final achieved energy savings were not dramatic, but they were real, real savings.

10. Financial Implications of Energy Savings

Many companies claim financial savings from energy efficiency without sources, sample sizes or numerical comparisons, often using business case software that predicts future savings. Actual financial savings remain the best means of comparison. A UK printing company successfully reduced energy consumption and costs through equipment upgrades, operational changes, staff engagement and the use of solar and wind energy. These interventions enabled substantial financial savings, demonstrating the economic viability of energy-efficiency investments in the sector.

Printing is energy intensive and consumes significant resources, yet wasteful practices prevail. A UK energy-regulated printing company’s initial investigation into energy consumption and wastage established consumption patterns and identified the root causes of the wasteful use of energy. An action plan was formulated and implemented to improve performance, reduce costs and decrease the environmental footprint. Beginning with an energy assessment and target-setting exercise, the plan focused on changing the company culture through staff training and awareness, upgrading equipment, and introducing smart metering and energy-use reporting.

10.1. Cost-Benefit Analysis

Energy efficiency denotes any measure that reduces the amount of energy required to perform a given task, activity, or process. Despite great efforts to design energy-efficient buildings, transportation, and industrial operations, much energy is wasted or lost before reaching the point of use. Industrial and commercial energy use constitutes a large share of total energy consumption, making these sectors logical and vital starting points for energy-efficiency improvements. By the same token, an industrial classification of energy use complements a sector-by-sector analysis of the worldwide potential for greenhouse gas mitigation.

Printing is an energy-intensive manufacturing process during which carbon dioxide is emitted. Fluctuating demand for carbon dioxide and rising energy costs have accelerated the requirement to reduce energy use during the printing process. Commercial and industrial entities are looking for opportunities to lower their energy use, whether reducing the consumption of fossil-based energy or complementing uses with renewable sources. For example, renewable resources of solar and wind energy are excellent options. Changing attitudes and energy-use priorities have prompted interest in detailed reporting budgets and energy consumption/usage analyses, and the introduction of smart energy meters can help in this regard.

10.2. Long-Term Financial Benefits

Energy efficiency means using less energy to perform the same task—in other words, eliminating waste. When something is energy efficient, it uses energy more wisely, reducing the environmental impact and saving money. The search for energy efficiency often concentrates on a particular product to link what you are already doing to what you should be doing within the printing industry.

The printing industry has a big energy appetite. Printing operations present many opportunities for energy improvements. By carefully assessing the dynamics of energy consumption, it is possible to reduce the environmental footprint and save money. What is being done and can be done to address these issues is illustrated through a working example from a UK company. Tackling energy use in the printing industry addresses the identified sources of wastage and avoids expensive repairs to now aging equipment. The gains on the environmental and financial efficiency side should never be overlooked; they can be surprisingly significant.

The first step is to identify the printing company's current energy demand, or create a request for that information from the utility providers. A goal should be to reduce the overall usage of energy within the printing plant and to move to a Green culture with awareness training and long-term thinking. Making the major push with a new, upgraded, energy-efficient press or coating machine is an obvious choice, but implementation of solar and wind sources of energy can also be important elements of the strategy. Monitoring printing-plant energy usage in real time and responsibility for it should be assigned. In the UK, smart metering is now being introduced that can widely help energy users to achieve their own efficiency targets. Finally, regular reporting of energy usage can also encourage long-term sustainable behaviour. The final figures for the financial savings—before any future financial benefits from the generation of electricity and the application of new government rebates—are shown in Table 10.3.

11. Regulatory Standards and Compliance

The importance of becoming energy efficient is generally well understood by most businesses and the motivation is quite often passive. It is widely appreciated that saving energy or installing energy efficient measures can generate financial savings, save money spent with utility companies and hence improve margins and profitability. Energy saving initiatives nevertheless continue to be overlooked either because of a lack of know-how or because the risks and hazards associated with the activity are not fully appreciated. The level of interest in energy saving initiatives and the amount of time and money invested is often not commensurate with the level of risk.

Regulatory standards can help to ensure that energy savings receive appropriate levels of attention and that every possible step is taken to identify and undertake profitable energy saving initiatives, where these can be achieved without jeopardising the health and safety of employees, the continuity of business operations or customer service levels. In the UK, businesses with an electricity consumption above 3GWh annually are obliged by legislation to measure and disclose their energy consumption. This is intended to focus the attention of electricity users on the amount of energy consumed by their activities in order to accelerate the adoption of energy saving measures.

11.1. Understanding UK Energy Regulations

A company wishing to reduce its carbon footprint and improve its energy efficiency needs to be aware of all the regulations applying to its industry. To introduce these, the printing industry is used as an example. Regulations in the UK require printers to measure and regularly report their energy use if they consume more than 40 kWh per annum of energy. These regulations, known as the Energy Performance of Buildings Directive (EPBD), were introduced by the European Union in 2002. With continued high fossil-fuel prices, increased taxation on fuel use and a drive to reduce carbon emissions, companies that can reduce costs by improving energy use are drawing attention in the UK.

The actual level of savings will differ according to the size of business and the types of processing operations. A printing company’s energy consumption is therefore examined, and a realistic possible savings level is calculated. It is estimated that savings of up to £13,000 per year can be realistically achieved by printing companies.

11.2. Meeting Compliance Requirements

Energy efficiency encompasses a range of methods that reduce the energy used to carry out any tasks, including everyday activities and industrial processes. When energy is wasted, extra and unnecessary energy must be generated, which harms the environment through pollution and greenhouse gas emissions. The printing industry is a significant energy user and static consumer of resources. Typically, during printing, the same resources are consumed year after year for identical production volumes. Much of the energy used during these processes is, however, wasted and not efficiently utilized. Much energy can be conserved using appropriate techniques, and energy management is seen as the most cost-effective method of satisfying a part of growing energy demand and environmental and social concerns.

A UK printing company began by establishing the area and quantity of energy wastage on its premises and setting achievable deadlines for running the business more sustainably. The production and administration buildings were examined to identify how they consumedenergy, and investments were made to replace inefficient and old equipment with energy efficient models. Awareness was raised among staff and training delivered to cultivate energy efficiency as a key element within the company culture. Solar and wind energy sources were installed to provide a supply of renewable energy needed in production, and a smart-metering system was established to give a clear picture of energy consumption. Reporting of energy usage and related cost implications is now addressed within monthly financial reviews. Acknowledging that improvements were difficult to achieve due to the technical limitations of current press equipment, as well as some resistance from staff due to changes in printing operations, the new approach nevertheless resulted in a saving of more than 20% of total annual energy costs. The financial cost of achieving these savings was significant, but the calculated energy savings were such that this expenditure will not only be recovered but will also see a reduction in ongoing operational costs.

Printing service providers in the UK are subject to a raft of regulations and standards covering environmental issues, and many of the energy savings described are the minimum level of energy monitoring, measurement and control expected by legislation and clients.

12. Challenges Faced During Implementation

Despite clear economic incentives, improving energy efficiency is often a low priority for businesses. A detailed evaluation specialist report on energy use at a UK printing company found that the main reason for artists and production people overlooking the problem, especially at crisis times, was a business culture featuring inflexible working routines and unsupportive local management. On a more practical level, some production machinery was not technically capable of accepting timing controls and often had to delay or spur production to maintain operational efficiency.

After a fruitful introduction of changes, a provision of clear, concise, accurate, and regular information on the business wasteful use of energy helped create long-term encouragement and awareness. The company also saved unimaginable real money and reduced carbon dioxide and carbon footprint. A thorough analysis of energy consumption can help any printing company identify ways to implement long-term energy savings, either by upgrading equipment or by encouraging employees to conform to energy-saving working practices such as turning off unused equipment. In many situations, the use of renewable energy sources, such as solar and wind energy, can considerably help. Implementing a sound energy-saving policy begins by monitoring the company’s actual energy usage, which is made simple with smart meters. Reporting the company’s energy use in the same way as its financial data further helps in implementing energy-saving policies. A company’s energy use is now regulated by a number of UK regulations specifically devoted to several sectors in the printing industry.

12.1. Resistance to Change

Resistance to change is a common challenge for any manager implementing new procedures in a well-establishedcompany. As well as providing staff training, there are other methods that can be used to encourage energy efficiencywithin any printing company.

Employees who operate older, less thermally efficient, heating or process equipment can be asked to consider withinthe context of their job role what environmental or energy concerns may be raised. It is also important that managersplan steps to transfer employees to newly installed energy efficient equipment to support their understanding of energysaving processes. This can be achieved by either upgrading existing equipment or by retrofitting accessories purchasedfrom organisations specialising in high efficiency motors, inverter drives, variable frequency drives and regenerativebrakes.

12.2. Technical Limitations

Certain pieces of printing equipment can restrict investments in energy efficiency. A UK printing company found that its older presses had a lower electricity demand than newer inkjet models, a fact that had to be considered when calculating the overall savings potential. Achieving a change in energy behaviour is generally easier when staff are able to turn machines on and off—something that was not always possible in offset printing due to requirement of the machines.

A broader strategy was to create a culture of energy awareness, instilling one of "energy behaviour change" within employees. The company used the offset department first to test the method, Chemical conversion coating (sometimes abbreviated to CC or CC-coating) serves as a protective coating for metal surfaces. It is typically applied to nonferrous metals such as aluminum or brass, though it is also effective on ferrous metals such as iron and steel. CS2 represents the adherence of the chemical coating to the metal surface and can vary depending on the metal type, which influences the coating's thickness. Commonly invested-in sources of energy savings in printing include solar panels, wind turbines, and smart metering.

13. Success Metrics and Evaluation

Identification of where energy wastage occurs is key to energy reduction initiatives, with a goal of developing methodologies that ensure the achievement of real financial savings in the UK case presented. Printing is an energy intense industrial sector, and printing companies are exposed to the adverse impacts of rising fuel costs. The control and monitoring of energy use is recognised as a research priority for the sector, to enable effective development of energy reduction targets and improvement measures.

Implementing a culture of energy awareness is central to energy efficiency programmes, and when employees are fully involved, real money can be saved. The experience of a UK-based printing company demonstrates how exposure to energy management issues opened managers’ eyes to inefficiencies within the works, resulting in significant reductions in energy consumption. An energy audit pinpointed specific problem areas, and the company sought advice on regulations and measures whereby it could reduce energy costs. A programme of employee training was started, along with upgrading to more energy-efficient equipment. Additional steps included the installation of solar panels to complement conventional energy supply, implementation of smart metering to monitor consumption patterns, and routine reporting of energy use. After overcoming some initial resistance and technical limitations of certain energy-saving devices, the firm achieved dramatic cost reductions and decreased its vulnerability to the effects of future fuel price rises.

13.1. Defining Success Metrics

Success can be judged by the energy saved in the print operation. By comparing the unit energy cost before the project start with the current unit cost (i.e. normalised for printing volume), it is possible to measure progress and success, as demonstrated by a UK commercial printer. This printer assessed its energy consumption and identified ways in which energy use could be reduced. Subsequently, systematic energy journal entries have been maintained, showing the steady monthly declines in energy costs per print unit.

Printing is an energy-intensive process, with consumption levels that make even small efficiencies worthwhile. The first step is to assess where energy is being wasted. Waste occurs not only by leaving machines running when not required or by neglecting to switch off downlights, but also by the inherent energy use of the manufacturing equipment. Older machines can consume energy inefficiently. The UK printer's experience highlights the practical financial benefits that flow from creating a culture of energy awareness through clear monitoring and reporting for all employees.

13.2. Evaluating Energy Savings

Energy efficiency is a popular term throughout the world, but the phrase can sometimes lack clarity. A practical definition is simply "useful output divided by total input," where the output could be work done, level of illumination, or level of comfort, and the input is the energy used to provide it. Much of the UK's existing building stock is energy inefficient, wasting valuable energy resources. Reducing this waste of energy also reduces emissions of carbon dioxide, the principal greenhouse gas causing global warming. Furthermore, increasing energy efficiency provides capacity within existing generation, transmission, and distribution infrastructure. It is therefore sensible to examine methods of increasing efficiency within existing industry.

The printing industry is one of the UK's largest users of energy and employs a significant proportion of the total workforce. However, the energy usage is not always immediately apparent. Inefficient machines are often the culprits of high energy usage, as they use a power mode and remain at that setting even when printing work is not required. Addressing such inefficiencies by installing more efficient plant and machinery and by ensuring that plant and machinery are switched off or put into low power modes when not in use can significantly reduce overall energy usage. An energy audit will indicate possible savings, but it is important to raise awareness among all employees and introduce training on energy awareness to establish an energy-saving culture throughout the company.

14. Future Trends in Energy Efficiency

Technology and best practices in energy efficiency are still developing, and the best approach for printing companies may be very different in the future. Until recently, the most-promising new technologies for printing companies were renewables such as solar and wind energy. The core energy efficiency principles remain valid but are merely one group of currently available strategies. Some of the more-advanced strategies, however, can create considerable challenges for companies.

Few energy-efficiency projects come without obstacles. Energy efficiency is often one of many issues competing for limited time and money within a company. Employees may resist changes that influence their work patterns, and switching to energy-efficient equipment may affect the quality of finished products or productivity. Energy Saving Trust research examined these issues in six UK printing companies. All had undertaken some energy-efficiency measures and had identified others that made commercial sense. The companies completed questionnaires and took part in interviews, which formed the basis for a comprehensive audit of their energy use. Energy savings of up to 30 per cent had already been achieved by upgrading equipment, introducing a culture of energy awareness, and implementing routine training and reporting. The auditors also estimated that the companies could make further savings of between 10 and 15 per cent.

14.1. Emerging Technologies

Increasingly, energy efficiency represents a primary goal for any company seeking to cut running costs. One UK printer has tackled the issue of energy wastage in printing and in printing equipment by changing to new processes, training employees, and investing in greener technology. For many companies, the perceived initial cost and disruption involved in making equipment more energy-efficient, and in implementing new working practices, produce inertia that delays the development of a green culture.

However, the company’s experience demonstrates that a change in culture can take place as soon as employees recognize that energy wastage costs more than a few extra pounds a month. The impact of shifting attitude through raising awareness should never be underestimated, especially when it is supported by enabling technologies—such as smart metering and energy reporting—as well as careful implementation; it proves possible even when industry regulation sets a low bar. In this printer’s case, the strategy included switching to renewable energy sources when these become feasible for a particular business, such as solar power and wind power. In addition, the company adopted energy-efficient products and energy-aware processes such as not heating printing rooms when unnecessary.

14.2. Industry Best Practices

Energy efficiency is defined as the percentage of input energy, which is put to productive use. Efficient technologies involve realistic goals for the use of energy for a specific process/application. In other words, energy efficiency entails reducing energy input without negatively affecting output, goods and services produced, or other desired outputs. Currently, the printing sector consumes a large amount of energy – mainly electrical. Therefore, identifying areas with very high consumption and associated wastage is imperative. Wastage can be mainly attributed to poor insulation, inefficient electrical equipment or older technology, under-maintenance, and the operation of machinery in an inconsistent or non-optimized manner.

A UK company has improved efficiency and introduced energy reduction measures. Smart energy metering is one such development that indicates and informs the user of real-time energy flow. The introduction of efficient technology can reduce consumption, and renewable technologies can also play a major role. Employees receive training to help create a culture of energy awareness. These improvements achieved reduced running costs and substantial operational savings. Regular energy usage reporting is used to assess progress and trend comparisons. Overcoming challenges during implementation was critical, as was evaluation. Future energy efficiency trends for the printing industry are considered.

15. Conclusion

Energy efficiency means using less energy to perform the same task, thereby eliminating energy wastage, reducing CO2 emissions, and saving money. The printing industry is highly energy intensive, with large amounts of lighting, heating, ventilation, power for printing processes, and ancillary equipment powered by electricity or gas or other fuels. The level of energy efficiency varies widely and some printing sites consume three or four times more energy than others. Inefficient sites have more equipment running than needed and, when equipment is old, such as lighting and ventilation, they use far more energy than modern equipment.

The energy consumption pattern of a typical UK printing company was analysed. Implementing the right strategies is required of printing companies to minimize the energy use and consumption in all phases of production and printing. Temporary downward changes in operating levels might also be achieved by energy zones and other organizational and operational controls. The steps taken to achieve energy efficiency within the company were demonstrated. Careful planning is required before developing such services.

A printing company was able to reduce its energy needs by £25,000 a year through upgrading equipment and encouraging a culture of awareness alongside retraining staff. Solar and wind energy are truthfully becoming viable options. Other changes include the installation of submeters and the generation of monthly reports on energy performance. Compliance with the UK Energy Efficiency Action Plan is mandatory, with print among 11 sectors that must disclose and manage their CO2 emissions. The results clearly illustrate the apparent benefits in terms of cost saving and CO2 mitigation achievable through improvement of energy efficiency in a printing plant.

If you need help with saving your energy costs in your printing business call us today. 03302 237 999 or contact us.