Apr 2006

1

Envelope Window Coverings

.

Impact on Envelope Recycling and Sustainability

Initiatives

EMA Plant Management CommitteeEMA Plant Management Committee

April 27, 2006April 27, 2006

Apr 2006

2

Window Coverings Agenda

• Envelope Recycling Envelope Recycling and the Impact of and the Impact of Window CoveringsWindow Coverings– ISRI / PSC– TAPPI

• Sustainability Sustainability Initiatives of Window Initiatives of Window Covering Covering ManufacturersManufacturers

Apr 2006

3

Recycling

Apr 2006

4

Collection – at office or home

Infrastructure RequiredInfrastructure Required

Apr 2006

5

Sold by Grade

• Soft Mixed (1)Soft Mixed (1)• Mixed (2)Mixed (2)• Sorted Office (37)Sorted Office (37)• Plastic Windowed Plastic Windowed

Envelopes (S-30) Envelopes (S-30)

• typically allow 0.5 – 2.0 % typically allow 0.5 – 2.0 %

prohibited materialsprohibited materials

Paper Stock Chapter

sets standards

Apr 2006

6

De-Inking plant

Apr 2006

7

Bale going to Pulper

Apr 2006

8

PulpingScrap Paper

+Water

AgitationHeat

Chemicals

Apr 2006

9

Solids Separation

FilmUV coatingsstaplespaper clips

inksclay

Apr 2006

10

Mill Comments• If the material is not useable If the material is not useable

fiber, separate it as early in the fiber, separate it as early in the process as possibleprocess as possible

• ““small bar on the pareto chart small bar on the pareto chart – nuisance problem”– nuisance problem”

• window envelope is preferred window envelope is preferred vs. an address labelvs. an address label

• shredding makes window shredding makes window coverings more difficult to coverings more difficult to separateseparate

• TISSUE MILLTISSUE MILLplastic adds to BTU value

Apr 2006

11

Paper Recycling - Summary

• CollectionCollection– grades of scrap paper that allow envelope window

coverings– There is no separation of envelopes by window

covering type• Pulping - Pulping - • De-trashing / ScreeningDe-trashing / Screening

materials removed include staples, film, UV cured coatings…

• Effect on EffluentEffect on Effluent– Envolution Study - Centre Technique du Papier International

Apr 2006

12

Envelope Window Coverings

• PolystyrenePolystyrene

• GlassineGlassine

• PLAPLA

• OthersOthers

Apr 2006

13

Sustainability’s Triple Bottom Line

The ultimate balance sheet, calling The ultimate balance sheet, calling attention to the three fundamental areas attention to the three fundamental areas

• economicseconomics

• environmentenvironment

• society society

Apr 2006

14

PLA Envelope Window Film Features

Uses significantly less Uses significantly less patch adhesivepatch adhesive

Outstanding wet fiber Outstanding wet fiber teartear

Great tear strengthGreat tear strength Remarkable stiffnessRemarkable stiffness Envelope and Envelope and

window can be window can be composted togethercomposted together

Can be Recyclable or Can be Recyclable or Repulpable in the Repulpable in the Repulping processRepulping process

Annually renewable and Annually renewable and sourced from a stable raw sourced from a stable raw material source – CORN ! material source – CORN !

Recognized by end users Recognized by end users as the environmentally as the environmentally friendly choicefriendly choice

Apr 2006

15

PLA Environmental Features

Greenhouse Gas Greenhouse Gas Neutral PolymerNeutral Polymer

Multiple sources of Multiple sources of annually renewable annually renewable feedstock'sfeedstock's Corn Wheat Rice Sugar Beets Sugar Cane

Can be recycled in a Can be recycled in a number of waysnumber of ways

Using 100 lbs of PLA film Using 100 lbs of PLA film instead of a petrol based instead of a petrol based film will:film will:– Save 50 liters(14 gal.) of gas– Power a 100 watt light bulb

for 8 months– Same as eliminating the

Carbon Dioxide emissions from an automobile over a 6-week period

• Clear Benefits that the Clear Benefits that the Consumer UnderstandsConsumer Understands

Apr 2006

16

Polystyrene & Petroleum

12 – US Dept of Energy

Apr 2006

17

Film Manufacturing

• Melt pellets and Melt pellets and convert to filmconvert to film

• Zero landfill policyZero landfill policy

• Most scrap is Most scrap is reprocessed reprocessed internallyinternally

• Residual sold to Residual sold to scrap plastic scrap plastic processorsprocessors

Apr 2006

18

Film Manufacturing

• Little scrap Little scrap generationgeneration– some edge trim– some start up scrap

Apr 2006

19

Packaging Material

• PalletsPallets• CoresCores• End boardsEnd boards• bandingbanding• stretch wrapstretch wrap

Apr 2006

20

Cores and End Boards

• Reused on thicker Reused on thicker films and sheetfilms and sheet

• End boards are sent End boards are sent back for re-useback for re-use

Apr 2006

21

Reusable Packing

Pallet that held master Pallet that held master rolls is cut in halfrolls is cut in half

Both halves are used to ship slit

rolls

Apr 2006

22

Film Manufacturing - Summary

• Zero landfill impactZero landfill impact– no plastic goes into landfill

• most reprocessed internally• minor amount sold to scrap dealers – like an

envelope manufacturer sells paper clippings

• Returnable PackagingReturnable Packaging

• Non returnable packaging is reusedNon returnable packaging is reused

Apr 2006

23

Reduce, Reuse, Recycle

• Use thinner film when you can Use thinner film when you can maintain productivity and qualitymaintain productivity and quality

Apr 2006

24

Questions?