News Releases

Nov.05,2013

 

Ecological Activity

DNP and DNK Develop Recycling and Reuse System for Heat Emitted by Deodorizing Apparatus for use by Dry Laminating Equipment

Expected to reduce drying device energy usage by 30 percent

 

Dai Nippon Printing Co., Ltd (DNP) and DNK Co., Ltd. (DNK), a 100 percent subsidiary of DNP engaged in the manufacture and marketing of printing equipment, have jointly developed a system for recycling and reusing heat emitted by deodorizer for dry laminating equipment. DNP targets a 30 percent reduction in energy usage from drying devices in dry laminating equipment as of July 2013. The new system will be introduced at the Chikugo plant in Chikugo City, Fukuoka Prefecture, which produces film-type packaging materials, where its benefits will be verified.

[Developmental Background]

DNP promotes Group wide energy saving activities targeting CO2 emission reductions. To date, the Company has promoted the switch to low CO2 emission energy, the use of natural energy and the adoption of energy monitoring systems in manufacturing facilities. On this occasion, the Company has focused on the fact that, as part of the manufacturing process for film-type packaging materials, dryers accompanying dry laminating equipment account for a significant share of total energy use, and has developed a recycle and reuse system for heat emitted by devices that recover and deodorize dry emissions.

[Overview of Heat Emission Recycle and Reuse System]

Emissions from the dryers used in dry laminating equipment contain Volatile Organic Compounds (VOC), and following VOC concentration in a concentrator, the VOC is incinerated, eliminated and deodorized at 800 deg C using a deodorizer. So far, the excess heat energy used to incinerate the VOC was used as a heat source for the steam boilers, but emissions at around 100 deg C were released into the atmosphere. The newly developed heat recycle system reuses these 100 deg C emissions as heat sources for hot air drying. Hot air drying has so far entailed heating the air to the necessary temperature with a drying device, then sending it to the drying zone of the dry laminating equipment. By using pre-heated emissions as hot air in the dryer, however, it has become possible to significantly reduce energy usage. At the same time, the temperature of the emissions recovered from the deodorizer is not stable, but by installing a heat exchange device that mixes emission heat exchanged air with air at external temperatures to adjust the temperature, the new system has made it possible to maintain the hot air temperature at specific levels. The Chikugo plant, where the system is adopted, sends hot air for drying to multiple drying zones from a single dryer, but drying temperature differs according to the drying zone, necessitating temperature adjustment on a drying zone basis. The newly developed heat recycle system is structured so as to obtain information on the drying temperature from each drying zone, forward the air at the temperature with the greatest emission usage rate, and use the temperature adjustment function of the dry laminating equipment to adjust each airstream to a suitable temperature.

[Heat Emission Recycle and Reuse System Features]

  • Uses heat from the deodorizer and reduces dryer energy usage by 30 percent.
  • It is now possible to optimize heat emission usage rates by suitably setting the temperature of the hot wind created by the system at the temperature necessary for the dry laminating equipment in the drying process.
  • By fine tuning the hot wind temperature with the adjustment function that the dry laminating equipment is already equipped with, it has also been possible to achieve existing thermal stability at lower costs.
  • Downsizing of the facilities has also been achieved by building in a heat exchanger into existing emission equipment.
  • A dedicated monitoring system for the new system has also been developed making it possible for administrators to perform real time confirmation of the running status and energy reduction amounts via the internet.

[Looking Ahead]

In addition to promoting the adoption of the newly developed system by other plants in the DNP Group that use dry lamination equipment, and developing heat emission usage systems compliant with drying devices in other production equipment, such as gravure printing and offset printing machines, DNP and DNK will make further efforts to reduce energy usage.

 

Dai Nippon Printing Co., Ltd.

Head office

Tokyo

Company president

Mr. Yoshitoshi Kitajima

Paid-in capital

144.4 billion yen

 

DNK Co., Ltd.

Head office

Ibaraki Prefecture

Company president

Mr. Satoru Inoue

Paid-in capital

100 million yen (DNP 100 percent)

 
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