Digital Magazine

Sustainability | Label Impressions Builds on its “Green” Reputation

Label and flexpack converter adds new energy storage system and waste removal system.

Label Impressions, Orange, CA, is expanding its operations into 30,000 sq ft in the fourth quarter of this year, reports President/CEO Jeff Salisbury. But one thing that’s not expanding is its carbon footprint. Label Impressions is installing an onsite advanced energy storage system, which will decrease costs by optimizing energy use. In addition, the converter has bolstered its commitment to the environment with the addition of trim and matrix removal systems.

As a green tag, label, and flexible packaging printer, Label Impressions produces high quality, high value products to end-users in California and nationwide. Specialties include folded booklet labels, expanded content labels, IRCs, cold foil label printing, scratch and sniff labels, rotary screen labels, and special effects printing.

The converter operates flexographic presses from 10 in. to 17 in. Primary markets are personal care, nutriceutical, natural products, agriculture, and pharmaceutical.

Expands Carbon Neutral Pledge

With the installation of a new JLM Energy Gridz system (watch video), Label Impressions can pull energy from the grid, store it during off-peak times, and redistribute this energy during times when utility costs are the highest. This optimization saves the company utility fees, allowing it to maintain very competitive printing prices.

Working with JLM Energy, Label Impressions will be able to increase its load capacity, which allows the company to add much needed additional equipment without increasing energy costs. “JLM Energy has worked closely with us to analyze our energy needs and design a system that optimizes our energy distribution,” says Salisbury.

“We look forward to building on this core Gridz with renewable energy options. In choosing JLM Energy, Label Impressions is selecting an ongoing partner for our green energy solutions.” This is the first step in realizing a master plan, including the potential addition of solar and wind energy generation on site.

Label Impressions reports it has the distinction of being the first label and packaging printer in the US to become both carbon neutral and FSC certified and is a leader in sustainable labeling. It continues to expand its green commitment with the addition of an energy consultant, which is assisting the company with ongoing evaluation and innovation. With new package printing equipment installed in 2014—eight- and ten-color Nilpeter servo film presses—that commitment has gone beyond labeling to the printing and production of flexible packaging.

JLM’s Gridz system provides a 30kW advanced energy storage system. The system actively works to reduce demand charges, saving money and keeping customers’ costs down. JLM Energy is unique in that it provides a portfolio of energy products that can grow and shift with business needs, all managed with cloud-based software. “There are other energy technology providers available, but only one that manufactures a full line of products, that work together to generate, store, and reduce utility demand charges,” says Nate Newsom, VP sales for JLM Energy. “We appreciate Label Impressions’ recognition of JLM as an energy partner, supporting their carbon neutral vision.”

Label Impressions’ JLM Gridz installation reportedly will:

  • Reduce energy expenditures using demand shaving technology
  • Utilize TOU pricing for effective charging and discharging of system
  • Enable installation of additional equipment up to 200–300 Amps
  • Provide real time energy monitoring system

Despite significant growth, Label Impressions limits its carbon footprint through aggressive lean initiatives, investments in waste reducing technology and equipment, and a continued commitment to reducing and offsetting carbon emissions. “Reduce what you can, offset what you can’t.” Salisbury notes.

Reduces Waste with Trim and Matrix Removal

Each week, up to 800,000 sq ft of raw material is unwound from rolls for processing at Label Impressions’ southern California manufacturing plant. After processing, trim and matrix from the rolls need to be rewound and manually removed. Occurring up to 90 times a week, this process costs hours of downtime and results in the loss of as much as 27,000 sq ft of raw material every week.

Recognizing the opportunity to eliminate this waste, Label Impressions is retrofitting its plant with a matrix waste removal system from Precision AirConvey. By seamlessly capturing and shredding waste from the presses, the system will eliminate the need for rewinding rolls of waste. This improvement will keep nearly 1.5 million sq ft of raw material from going to waste each year.

The PAC system also will enable Label Impressions to purchase material rolls with thinner edges, further reducing raw material use by 1.67%. In total, the improvements will save Label Impressions an estimated $210,000 annually: $132,000 through reduced material costs and $78,000 through eliminated downtime. The system will pay for itself within a year, proving that environmental and cost-consciousness can go hand-in-hand.

“This new system demonstrates Label Impressions’ continued commitment to implementing environmentally friendly solutions at each stage of our production process,” says Salisbury. “We’re very pleased and excited to see the impact the PAC system will have on reducing our carbon footprint, as well as supporting the financial health of our company.”

Thomas Embley, CEO of Precision AirConvey, Newark, DE, added that the partnership was equally rewarding for his company. “This installation is not the product of chance, but of design,” he said. “We’re delighted that they chose us from across the country.”

By capturing and shredding waste from the presses, the PAC system will eliminate the need for rewinding trim and matrix.


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