Initiatives & Milestones

• Royle Printing is certified to the Forest Stewardship Council® (FSC-C022017) Chain of Custody Standard and partners with paper companies that continually participate in certification programs.

• We upgraded all lighting in our facility, installing state-of-the-art Orion Light Fixtures. We have upgraded half of the Bird Street plant to LED lighting. The Success Way location is completely LED. The investment saves approximately $57,000 in annual savings and 107,500 kWh in displaced energy.

• We routinely conduct energy and operational audits; discovering areas where process improvements and investments will reduce operating costs and any impact on the environment.

• We installed a new Regenerative Thermal Oxidizing (RTO) unit to handle emissions from our heat set web presses. The effectiveness and efficiency of this system allow us to emit 99.5% pure air back into the environment (OSHA requires a minimum of 95%). This investment in technology helps convert heat into energy; providing power to our facility and equipment. We reclaim heat and energy from the RTO unit; reprocessing it into heating and conditioned air for our facility.

• We’ve upgraded to Contiweb hot air dryers with integrated afterburners, significantly reducing Royle Printing’s gas consumption and carbon footprint. The integrated afterburner burns the solvents from the ink, leaving 99.9% clean exhaust air. This is well above the OHSA’s standard, which requires a minimum of 95% clean air emissions back to the environment. The thermal energy gained from burning the solvents is effectively being re-used in the heating process of the dryer. The Solvent Concentration Control reduces the purge fan speeds to reach the highest possible solvent concentration resulting in the industry

• We replaced chill systems on all presses and created a centralized compressor, thereby vastly reducing the area to save energy.

• With our partners in the paper industry, Royle plays a role in recapturing almost 70 %of all paper products used in the printing and packaging industry. The recaptured paper is then recycled.

• Royle bales all scrap paper, selling it to various paper manufacturers. These manufacturers convert the waste into pulp, creating pre-and post-consumer waste paper and paper boards.

• Royle invested in energy-efficient details when building two 40,000 square-foot additions, including rows of windows facing north and south to allow natural sunlight into the facility, light sensors that only turn the lights on when there are not enough external light, motion sensors that turn lights on/off depending upon employee entrance/exit, and two large 24-foot fans and four 16 foot fans to circulate air and depress heat closer to the floor.

• We installed make-up air units to save energy and eliminate negative airflow within our facility when any exterior door opens.

• Royle’s transportation fleet is state of the art, employing the latest technology to maximize fuel mileage, reduce idle time, and eliminate air drag. Both our Peterbilt and Freightliner are certified clean idle.

• Royle’s inks are heat-set inks containing 5% - 7%vegetable oil. These inks have a Bio-Renewable Content (BRC) index of 20. A BRC index of 20 indicates that 20% of the printing ink is made from bio-renewable resources (such as soybean oil, castor oil, and tall oil rosin).

• Royle utilizes Fujifilm SUPERIA ZX plates for all presses to help reduce waste and chemicals in the environment. The plates’ key environmental impacts are energy conservation, water consumption reduction, and reduced emissions of the plate processing steps.

• 24.3% of the power utilized by Royle is Renewable Energy and we are enrolled in the city of Sun Prairie’s “Power Wise” Energy Efficiency Program.

• Utilization of electric forklifts.