progress storage area. Structure Special structure has 170 foundation piles supporting the concrete fl oor. The
walls and roof uses pre-fabricated concrete structural panels with a tectonic
fi nish. The roof is protected by lightning rods. The lower half of walls are
concrete, with the upper walls in laminated board with polystyrene insulation. Flooring Cast concrete with a maximum load intensity of about 6t/m2 to support 120+ tonne 10-colour press. The fl oor has a multiple layer painted fi nish. 2
THE PARTICIPANTS IN THE PROJET President of the company Dr. Hirokazu SHIMIZU ✖ ✌ ✏ ☞ ✄ ✁ ☎ ✁ ✆ ✡ ✄ ✞ ✑ ☞ ✡ ✍ ☎ ✏ ✗ ☞ ✌ ✞ ✘ ✞ ☎ ✗ ✆ ✠ ✠ ✞ ✗ ✗ ✍ ✏ ✠ ☞ ✁ ✟ ✗ ✁ ✍ ☞ ✌ ✞ ✝ ✟ ✁ ✙ ✞ ✠ ☞ ✕
- The project began with the strong idea to provide the best production
environment for UV production as core facilities, including the capacity to install long presses.
- Separated rooms also enhance customer satisfaction because the can independently host different print buyers for quality checks at the same time.
- All peripheral equipment (pumps, compressors, water cooled chillers) are located outside the press cells to avoids their related temperature variations. This optimizes air conditioning effi ciency and reduces noise level in the press rooms.
- Development of trusting relationships between our factory managers, equipment suppliers and the construction company allowed them to work very closely to achieve the fi nal goal. The architect - Builder Nagura Co. Ltd. ✖ ✌ ✏ ☞ ✄ ✁ ☎ ✁ ✆ ✡ ✄ ✞ ✑ ☞ ✡ ✍ ☎ ✏ ✗ ☞ ✌ ✞ ✘ ✞ ☎ ✗ ✆ ✠ ✠ ✞ ✗ ✗ ✍ ✏ ✠ ☞ ✁ ✟ ✗ ✁ ✍ ☞ ✌ ✞ ✝ ✟ ✁ ✙ ✞ ✠ ☞ ✕ - The client clearly defi ned their primary design concept at the beginning of the project was to produce the best printing quality — it was then not so diffi cult to convert their exacting goals into tangible form.
- Their focus on combining the best quality for special printing, along with eco friendly effi ciency, allows them passionate and dual directional communication.
PROJECT CONCEPTION/ SUSTAINABLE CONSTRUCTION Origin of construction/reorganisation. The previous site was located in the centre of Tokyo and surrounded by high-rise apartments and offi ce buildings and the co-existence with a factory was not easy. It was also too small to allow a change of business focus to packaging — that included installing a new long press for special UV printing. We needed a new building that combined the best properties of a manufacturing centre while also providing an exhibition area for sales activities to attract new clients. We fi nally found a site of ancestral importance that is near the birthplace of our founder (grandfather of current CEO). Motivation for an ecological construction An eco-friendly construction was one of the key factors for the building design since our business concerns responsible manufacturing, e.g. waterless printing to reduce water use, high defi nition printing to reduce ink consumption, carbon footprint evaluation to lower environmental impact and so on. Energy reduction related to eco-friendly issues was a preferred consideration for both environmentally conscious manufacturing and cost savings. Project organisation The project concept was originated by the CEO and implemented by the Nagura construction company who have been a sole supplier to Shimizu because they have a good track record for construction of our other buildings over 60 years. Planning During the fi rst year we examined 10 sites to fi nd the best geographical environment to meet the project’s objectives. During the next 10 months, the building design was developed from the specifi cations of new production facilities — UV presses, die-cutters and gluers. The construction took around 9 months — a bit longer than for a conventional building because of the “more than enough” construction approach for heavy printing machines. Cost of works (excluding investment Total cost for building the new factory was around 5.5 M €, including 2 M € for in production) the site. Durable construction cost Estimated eco-friendly specifi cation costs about 30% morer than for a conventional construction. Direct and indirect impact on the production Maintaining optimum temperature and humidity for UV printing with smooth non-stop feeding on a range substrates delivers superb printing quality and productivity. In addition, most employees live within a 10-minute drive from the factory to avoid them commuting in overcrowded trains that triggers fatigue, this minimises severe mental and physical stress at work. Principal sustainable characteristics — The separate enclosures for each core production facility helps reduce energy pillars for HQE® consumption and related green house gas emissions and is fundamental for high quality printing. Locating the press peripherals (pumps, compressors and chillers) to a separate room further stabilises production conditions. Public or private fi nancial aid No fi nancial aid was applied for the project. 4
Rainwater from the roof is collected into a large basement tank for fi re control. Reduction actions UV waterless printing reduces water consumption because there is no dampening system.
Drained water is collected and fi ltered by 4-level purifying tanks to lower its pollution level to allow discharge to the river.
The CTP developer has a liquid compression device (strong alkali) to reduce its waste to 12,5% of total volume and returns 87,5% of fi ltered water back to the developer this drastically reduces both prepress water consumption and liquid waste disposal. The company is implanted in one of the hottest zones in Japan. The air conditioning units are cooled with a water spray. To limit consumption, the cooling system uses fi ne water drops for two hours per day. ENERGY Consumption Annual electricity consumption is 1 280 000 kWh. Electricity is the primary energy supply, no gas is used. Total energy cost is 3,5% of turnover. Principal sources of consumption are:
- Production equipment and Air conditioning units
- Offi ce and workshop heating (by electricity)
- Central compressed air system
- Electric lift trucks Estimation of need Energy need was estimated from the base of past consumption. Reduction actions Electricity costs in Japan surged after the Fukishima tsunami closed down most nuclear power plants. Therefore “visualization” of electricity use is a key to reduce electricity cost. Electricity monitoring devices measure rated outputs and load factors of all production facilities including peripherals. This allows peak energy (kW) and consumption (kWh) to be estimated and forecast by looking at the production schedule and operational status of facilities.
UV curing devices have a much higher electricity consumption than conventional presses. Consumption is regularly checked by measuring the exact amount of electricity needed to cure UV inks at the lowest energy. Monitoring A web camera in the high voltage receiving facility transmits current use to a server that managers can access on their PC, tablet or smart phone. The monitoring device software calculates forecast and actual kW and kWh. It sends an alert e-mail if electricity use overruns target value that is usually set lower than that of the same day the previous year. 5