The 1990s marked the heyday of heat-set web offset printing, with one web offset press after another being installed. Simultaneously, a significant number of hot air dryers were deployed to facilitate high-speed production. While these dryers are generally sturdy and resilient, they don't last forever. Innovations and shifting market conditions have even made it worthwhile to replace them before they reach the end of their technical lifespan. In this blog post, we'll delve into the market conditions driving this shift and explore the positive impacts that a new dryer can bring.
Unexpected Downtime Due to Ad-Hoc Repairs
Hot air dryers used in the web offset print industry face formidable challenges. The burner chambers, in particular, endure significant temperature fluctuations, leading to constant expansion and contraction. Additionally, the continuous operation of various motors and moving components, often without respite, puts a strain on the equipment. Even if a dryer receives exemplary maintenance throughout its lifespan, costly repairs with extended downtime become inevitable as time passes.
Unscheduled repairs can be particularly troublesome, causing significant disruptions to the timely delivery of print work, which is paramount to the customer. As a dryer approaches the 25-year mark, its technical condition often prompts printers to consider replacement. When evaluating the possibility of replacing the old dryer with a new Contiweb model, the business case frequently reveals substantial cost savings and an unexpectedly short payback period.
High Energy Consumption in Printing Companies
The majority of these savings are realized by heat-set web offset printing companies currently utilizing a central afterburner to incinerate the solvents released by the dryers in their printing press lines. During the ink-burning process in the dryer, solvents are emitted with high levels of CO2. These solvents are subsequently directed from the dryer to the central afterburner. Operating at temperatures around 800 °C (1500°F), the afterburner consumes a significant amount of gas to eliminate volatile organic compounds (VOCs) and produce clean exhaust air.
From Contiweb's perspective, burning these solvents in a central afterburner is wasteful, as they could have been utilized as fuel for the dryer. By opting to burn them in the central afterburner rather than within the dryer itself, valuable fuel is squandered. Additionally, the central afterburner requires extra fuel to burn this 'free fuel'.
Huge Cost Savings through Efficient Drying Technology
This is where Contiweb Ecoset and Ecodry dryers come into play, revolutionizing this process to be highly efficient. These dryers incorporate an integrated afterburner that incinerates the solvents present in the ink. The thermal energy generated during the combustion of solvents is efficiently reused in the heating process, resulting in a substantial reduction in gas consumption.
Furthermore, the streamlined path the hot air follows to reach the paper web ensures that the fans require minimal power to transport the hot air. Additionally, Contiweb dryer fans are equipped with state-of-the-art motors that precisely adjust the circulation speed to meet the specific requirements of the printing press. This, once again, results in a substantial reduction in electricity consumption and, as an added benefit, prolongs the lifespan of motors, motor bearings, V-belts, and fans.
The reduction in gas and electricity consumption translates into substantial savings and contributes to reducing the consumption of fossil fuels.
An excellent real-world example is Roularta Printing, part of Roularta Media Group. Roularta Media Group is firmly established within the Belgian commercial printing world as a market-leading producer of magazines in both French and Dutch, while also being the second largest magazine publishing company in the Netherlands. Following government initiatives in 2010 to improve sustainability practices within businesses, Roularta has been at the forefront of green and environmental growth within the printing sector and has made it the company’s mission to find solutions that improve the practice. As a result, the management team identified Contiweb dryers to reduce gas consumption in accordance with the company’s ISO 50001 certification.
In July 2023, Roularta installed a new Contiweb dryer, and two more Contiweb dryers are scheduled for installation before the end of 2023. The company recently disclosed the savings achieved with the replacement of the first dryer, which include:
- 50% less gas consumption
- 30% less electricity consumption
- 14% less CO2 emissions
Government Subsidies for Green Capital Investments
Thanks to the cost savings, the business case for a new dryer often proves favorable. Additionally, governments worldwide offer subsidies and incentives to companies that invest in capital goods to reduce their carbon footprint and reduce consumption of fossil fuels. These subsidies are part of broader initiatives addressing environmental concerns and climate change, aiming to encourage companies to adopt cleaner technologies and practices. The availability and nature of these subsidies vary from one country and region to another.
The European Union is particularly committed to an ambitious climate policy. With the Green Deal, it aims to become the first continent to balance CO2 emissions and production by 2050. This goal became legally binding when the European Parliament and the Council adopted the Climate Law in 2021.
Some printing companies, like Roularta Printing in Belgium, have even higher ambitions. Steven Renders, General Manager of Roularta Printing, asserts, “Our aim is to achieve carbon neutrality by 2040, 10-years faster than the EU target and our strong financial position affords us the opportunity to accelerate those plans.”
Let Us Calculate Your Savings Potential
For printing companies committed to the heat-set web offset industry it is worthwhile to consider replacing aged dryers, even ahead of their anticipated lifespan. This proactive approach to dryer replacement serves not only as a means to prevent unexpected downtime but also as a strategy to maximize cost-effectiveness while minimizing environmental impact. Rather than waiting for natural retirement, considering an early dryer replacement can prove to be a judicious financial decision for your business.
Thanks to the Sustainable Savings Estimator on our website, you can easily and without any obligation get an indication of the potential savings in your specific situation. Of course, you can also reach out directly to your Contiweb contact person for more information.
The future of printing is greener and more cost-effective, and Contiweb is here to help you make the transition.
