A DRIVE FOR
POWER CONSERVATION IN PRINTING PRESS
Power is consume in various ways across all the sector of Indian industries and homes, it consume vital
natural resources to convert the energy from one form to another. Much of the energy is consume usefully, but some
amount of energy get wasted or lost in the system. This may be due to lack of knowledge, interest or less efficient
system, this article is aimed to get aware of “waste of energy” which must be addressed.
It is observed that an organization like a printing industry normally no one is directly responsible for the
monitoring, control and waste of power. Each company have its own characteristic, on need based monitoring and
targeting system to meet its own requirements, but the Energy is a recurring direct cost to the company and for the
nation too. The availability of energy for industrial infrastructure on sustainable basis is important and must be
ensured. The growth of printing industries in Indian market is abruptly increasing; hence the demand of electrical
energy is growing and it’s directly consuming natural resource which is depleting fast. Thus there is need to
conserve energy, particularly print industry is strongly felt that the energy cost takes up substantial share in the
overall cost structure of the operation. This economic inspired to take the initiative and promote the conservative
drive among print industries.
According to the report, the Central Electricity Authority of India has projected an energy shortfall of about
10 per cent for this year. Saving or conserving the energy of about 10 per cent or more in an organization is not the
big target goal; we can initiate to save energy to compensate the shortfall and additionally to save organization
revenue. Among the various strategies to be evolved for meeting energy demand, efficient use of energy and its
conservation emerges out to be the least cost option against any given strategies, apart from being environmentally
benign.
It is the well known fact that each driver knows mileage of its vehicle, how many kilometres to a litre that
he can drive out his vehicle, but very few printers know how much energy their printing press consumes each time
they run or across the month. It is understand that, fuel millage of the vehicle and its technology has become a key
factor in its selection, and so energy consumption and technology is playing an emerging important role in the print
press process. Presently the print manager gives priority to its production only, but it is a question for the printer to
know precisely how much power his press and its utilities are consuming, what are recyclables? How losses or
wastages can be avoided? And off course, what best else printer can do for the organization in limited available
resources?
As a printing organization we use a great deal of energy to manufacture our products. In a typical press set
up for offset printing machine the major power consumption load are in a ratio of, press – 78% (68%), utilities –
08%, Light- 06%, & Air conditions – 08% (18%). The energy manager of the company must able to decide the key
area for saving, easy approach and fast results. The method adopted and result area selected by manager may lead
the time line and amount of compensation to the company.
Power shortage situation calls for energy conservation, which essentially means using less energy for the
same level of activity. The approach to create sustainable energy system and to have better technology, the
management of organizations can form a team that includes the printers, technocrats and utility technicians. For the
successful Energy management & implementation system, the knowledge of process & machine for the leader is
very important. The formation of such teams in individual presses for energy conservation program will lead the
printing industries to the new horizon; this will make new bench mark in terms of energy profitability. In a studies
made out of 20% saving in energy in industries, have shown that 5% savings come from Good House- keeping,
another 5% comes from conventional technology. And 10% comes from Innovation and development from the work
respectively. Today power has become a prime factor in deciding the product cost at micro level & in dictating the
inflation and the debt burden at the macro level.
Now having established need for energy conservation, a systematic approach need to be discusses and
conclusions are required. Some of the organizations may have taken initiatives and they are training all concern
employees to initiate in this direction. There is no need to appoint separate man-power; the active technical members
of company can drive through the opportunities in this field which not only save energy for company or for nation
but for all humans. Proper use of available resources, energy efficient press & utility and technically develop all
system is the main mantra that leads to sustainable energy management. The role of the energy management team
players can be defined as
a)
b)
c)
d)
e)
f)
g)
h)
i)
Prepare an Energy Management policy for the company
As per their concern and level, all employees training
Implement the guidelines issued by the chief energy officer
A fix time or periodic inspection
Audit of energy drives & initiatives
Review and monitor of energy consumption
Accountable for “Reduce the energy consumption and set new targets”.
Carbon foot print reduction and calculation
Preparation feed- back and records forms.
It is well said that “EVERY UNIT SAVE IS EQUAL TO UNIT GENERATED”, but if we see from the side of
public utility system this phrase become more effective. The transmission and other losses gets add up, and it
can be said as “EVERY UNIT SAVE REDUCE TWICE THE UNIT GENERATED”.
Returning back, the overall economic structure of a company is usually the most important factor affecting
the management decision to apply on conservation and technology system. In particular the benefits arise from the
reduction of output losses and proper maintenance of equipment give good saving from the conventional technology
methods which may be as high as 10% as compare to badly maintained machines, and where as the printing
machines is the major load in plant. On day to day basis every effort must requires to be made to educate & trained
all employees in industries to make complete system most efficient, as Energy cost is a significant factor in company
and for nation economic activity.
A great improvement can be achieved in adoption of new technology; this can be plan and design at the
time of installation of new plant or can be use as equipment retrofit. They are available in the market and our
government is promoting such type of conservation products & policies, taxes rebate on energy conservation
products, Bureau of Energy Efficiency (BEE) a government body gives the guide lines for better efficient product
by giving star rating mark on such products. The low power consumption devices should be install in press and
energy efficient system which give direct as well as indirect saving must be preferred, like the LED light in printing
plant in place of high bay light or conventional light give almost 70% cost reduction, thus calculating the return on
investment is about two and half years. Similarly use of ‘Presence detectors’ in air condition cabins or staff sitting
area give again good saving. Harmonic currents and low power factor created by non-linear loads that may be due to
printing press DC drive, UPS, variable speed drive for air compressor or chillier pumps, not only result in possible
power factor penalties, but also increase the power losses in a distribution system. A various technique, methods and
equipments are available not only to improve the system losses but also give the incentives recommended by public
utilities.
Industrial energy use globally 40% of electricity, 77% of coal and coal products use, and 37% of natural
gas use and these are the major contributor to CO2 emissions. It becomes perception that energy efficiency of the
industrial sector is too complex to be addressed through public policy but it observed that industrial facilities will
achieve energy efficiency through the competitive pressures of the market place alone. The competition pressure and
hike in raw material prices keep industry to think again for saving from various wastages and losses.
On concluding, I humbly pay thanks to my office seniors and colleague those who motivate and support me
to expedite on this endeavour, and off-course to ‘All about newspapers’ who has given me a platform to open my
view to drive power conservation.
“CONSERVATION DOES NOT COST MUCH, BUT SAVES A LOTS, MAKE IT HABIT”
By;
Kapil K. Mathur
(BE Electrical, PG Dip. in Management,
ME Power system)
Asst General Manager – Engineering
Technical Corporate
Dainik Bhaskar
D B Corp Ltd.
Jaipur India