Going green has been an industry buzzword for some time now. While this is true across all industry segments across the world (carbon footprint, greenhouse emission, fossil fuel, you know the terms), the concern has been especially acute in printing industry. For one, the industry uses hazardous materials, such as solvents, which can pose danger to both human and environment if not properly disposed.
We, at PrintWeek India, are equally concerned. This is the reason why, to promote the green cause, we have introduced the category PrintWeek India Green Printing Company of the Year in our annual PrintWeek India Awards.
The awareness is there, but most print firms have failed to do anything substantial about it other than offering lip services. After all, going green means moving away from the traditional way of doing business, and it is a costly proposition.
This is where Greater Noida-based Nutech Packagings stands out. The company is not just talking the talk, but walking the walk. And how?
The company recently shifted its base from its existing plant in Noida Sector 7 to a state-of-the-art two-storey plus basement newly constructed facility in Greater Noida. Shifting is in process and complete shifting will take more four months.
Often we use the word state-of-the-art in a loose sense. In this case, however, the facility is truly state-of-the-art. No, we are not talking about the machines the company has recently acquired, including the new generation Scodix, the country’s first Scodix E106, which the company finalised at Drupa 2016.
It is the plant itself, the building which houses these machines, is state-of-the-art.
To begin with, the building is in process of receiving the LEED certification from the UK, and it will perhaps be the only print firm in India, besides Tetra Pak. The Leadership in Energy and Environmental Design (LEED) is a rating system devised by the United States Green Building Council (USGBC) to evaluate the environmental performance of a building and encourage market transformation towards sustainable design.
To put the achievement in perspective, the Abad Nucleus Mall at Maradu in Kochi is India’s first LEED certified gold-rated green mall.
“The United Kingdom chapter of LEED, has collaborations with the Indian Green Building Council (IGBC),” says Jatinder Shroff, the owner of Nutech Packagings. He adds, "This LEED certification will be the kind of recognition that brands value and in some cases a necessity."
A green plant
All this has been meticulously planned. The new building has the basement, ground and first floor constructed in such a manner that the packaging company would be able to use maximum sunlight and would require minimum power to light the interiors. “We have used green glass for our plant and more than 74% of natural light will come from those to the office area and the factory,” Shroff explains.
Print production usually generates heat. Hence, the company has used heat reflection paints on outside walls and on roofs. Those paints reduce temperature up to 15 degrees Celsius. “We have used ACC blocks instead of conventional bricks for better insulation of air. We have also used mud, sand and other natural material to keep our roofs cool,” Shroff adds.
The front of the plant is fully green, with organic plants and special grass. “Earlier, we were focusing on grass, but our green building consultant suggested that trees are better than grass, as grass consumes more water,” says Shroff. “Another initiative we have taken is rainwater harvesting. We have constructed three rainwater harvesting pits, where we have inserted pipes of eight-inch radius and 80-feet length.” The packaging company is also adding special kind of material below roofs to reduce the temperature.
Nutech has also focused on recycling of liquid waste. “We have established a Sewage Treatment Plant (STP) with a capacity of 15 KLD and Effluent Treatment Plant (ETP) of 3 KLD. We will use the water for flush and plantation,” he said.
The company is also focusing to reduce the consumption of water, and this includes using less water in toilet flushes and wash basins as well. “We Indians, especially North Indians, have the habit of using more water. It is tough to change our habits in one day, but we can control these by controlling the supply of water,” Shroff explains.
Now, Nutech wants to harness the power of solar energy. “The sun is very kind to us. We can use its energy for our office purposes. We are planning to have a setup for 100 kw solar energy,” he said. “The ratio between natural and conventional energy in our plant will be 1:10 and we will try to increase it. For saving on power, we have installed all LED bulbs and tubes. It is 30% expensive compared to conventional equipment, but it is worth it.”
The total area of plant is 10,000 sq/m and the size of the constructed area is 130,000 sq/ft with open area for future expansion.
Esko, Heidelberg, Scodix, Tiancen at Nutech
Beside the Scodix E106, the B1-size print enhancement equipment, in the recent days, Nutech Packagings has invested in a raft of high-end machines, including a seven-colour Heidelberg, an offline lamination machine from Tiancen, a China-made stripping machine, and an upgrade in Esko Suite, QC lab, and other small equipment. Besides, Nutech boasts to have North India’s lone single-colour rotogravure sheetfed press for printing specialised metallic colour, a HC Moog.
“The Scodix is our latest investment. This machine will be installed in the middle of the next year,” Shroff says. “We found the Scodix to be the best solution for print enhancement.”
The machine can be used for spot UV, embossing, foiling, cast and cure with a speed of 4,000 sheets of B1 and 6,000 sheets of B2 size.
The seven-colour Heidelberg was the company’s biggest investment last year. “The Heidelberg CD 102 seven-colour plus coater press is carbon neutral. This is a combination press with UV and IR drying systems and closed loop colour management. Online foiling system can be added in future. Its base is more than 500 mm higher compared to normal printing press,” says Shroff, adding that the UV printing press gives the company confidence to produce jobs on multiple substrates. The press can print a sheet size of 28x40 at the speed of 15,000 impressions an hour.”
The company has also invested in a Heidelberg Prinect MIS.
A Sedex member
The goal, of course, is to be the best in the chosen market – high-end packaging, both long and short runs. For this, Shroff has covered all the grounds. Again, to reiterate, this is what makes Nutech Packagings stand out. While other print firms may scramble for this or that certification because their clients want it (multinational clients want all the possible certifications from their printers), Nutech is ready with the best of the world.
Thus, the company achieved another milestone rarely seen among Indian printers – a Sedex membership. Sedex is a not-for-profit membership organisation dedicated to driving improvements in ethical and responsible business practices in global supply chains. The innovative and effective supply chain management solution helps reduce risk, protects company reputation and improves supply chain practices.
Sedex has two main aims, to ease the burden on suppliers facing multiple audits, questionnaires and certifications and to drive improvements in the ethical performance of global supply chains.
With the new facilities in place, Shroff says, the company expects around 60% increase in its total conversion of paper and board.
On cards is the plan to expand its corrugation portfolio, adding flute G production. “We manufacture A, B and E-flutes and now adding G,” Shroff says.
Nutech has an employee strength of 150.