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Description
Our company designs and manufactures flexographic polymer moulds for flexographic printing houses. The project is an extension of the company''s specialisation in making sets of photopolymer printing forms (matrices) to order. It is aimed at implementing an automated process of washing out and processing photopolymer moulds, which will make it possible to obtain high quality and repeatable images on printing forms. The company will market improved environmentally friendly photopolymer printing forms for printing on corrugated cardboard packaging, labels and flexible packaging.
The project will eliminate paraffin from the production of matrices and from the working environment as the new line will etch print moulds in an automated manner and adapted to the eco-friendly solvent Fs90i, which also reduces solvent emissions by 40% compared to traditional solutions. Hazardous waste consumption will be reduced with the purchase of a distillation unit that operates without oil. We currently produce 1 tonne of waste oil annually and the new process will reduce this by 50%. Green solutions will reduce CO2 emissions by 38.25 tonnes per year, and electricity demand will be reduced by 0.05 GWh as a result of a 50 kW photovoltaic installation.
In addition to the purchase of the technological line, distillation unit and photovoltaic panels, the project plans to commission a scientific unit to test the solution used in order to obtain a better quality of the print mould etched with additional brushes for microstructures, as well as to test the increased optical density of the ink from the prints supplied.
Summary of project results
The main problems/needs that will be solved and satisfied as a result of the project implementation include:
- Washing of printing forms with ordinary solvent
- Manual processing of printing forms
- Traditional etching processors
- Lack of distillation infrastructure that does not require oil to heat the solvent, which after processing is a hazardous waste
Major issues resolved:
- washing out printing plates with ordinary solvent; Currently, printing plates are washed with an ecological solvent in 70%, after the project implementation printing plates can be washed 100% ecologically.
- manual processing of printing plates; As part of the project, the process of automated processing of printing forms will be implemented.
- traditional etching processors. As part of the project, an etching processor adapted to the production of microstructures will be implemented (pattering, digicap)
- lack of infrastructure for distillation, which does not require oil to heat the solvent, which after overworked, it is hazardous waste - the necessary infrastructure was created.
Beneficiary of P.P.H.U. "PolimerPro" s.c. achieved the following results as a result of the project implementation. The necessary infrastructure was purchased (increasing the technical base in the company, in the form of purchase new fixed assets), which consists of:
*Flexographic die production line with a processor connected online to the dryer,
*Distilling device,
*Photovoltaic installation
As a result of the project, cooperation was established with the Polish Scientific Unit. Obtaining funding from the Norwegian Funds was promoted on the website and in the media social media. As a result of the project, solutions were introduced that have a positive impact on the Beneficiary because they have influence on:
- increasing revenues in the company, already in the first year after the project completion;
- increasing employment of at least 1 person;
- reducing annual CO2 emissions;
- reduction of annual electricity consumption;
- reducing the amount of hazardous waste.