Process Optimisation in Print Manufacturing
Energy Challenges in the Print Sector
The commercial print manufacturing sector is under mounting pressure, with energy costs now one of the most significant operational challenges facing the industry.
At the same time, the shift towards more sustainable, energy-efficient production has become business-critical. Printing environments depend on energy-intensive press operations, drying systems, and finishing processes that run continuously, driving high levels of consumption. The message is clear: every unit of energy used has a direct and growing impact on the bottom line.
Solvent Monitoring and Control
For print manufacturing facilities using solvent-based inks and coatings, solvent use is a critical but often overlooked area of energy loss and cost. Without accurate monitoring, excess solvent consumption can go unnoticed, increasing both operational spend and environmental impact.
As part of our on-site assessment, we analyse solvent usage and its impact on drying systems and thermal oxidisers. By identifying where excess solvent is being used or lost, we help reduce material waste and lower the energy required for evaporation and treatment.
Process Energy implements LEL solvent monitoring that give you clear visibility of usage across your process. By tracking solvent consumption, you can identify possible risk areas in your facility.
This not only lowers material costs but also reduces the load on drying systems and thermal oxidisers, cutting overall energy demand while supporting compliance with environmental regulations.
Our Energy Assessment Process for Commercial Printers
Process Energy’s engineers carry out a physical, on-site energy survey of your facility, measuring energy consumption, heat flows, and inefficiencies across your key processes, from press rooms and drying systems through to compressed air, ink-drying systems, and climate control.
Working alongside your engineering team, we pinpoint exactly where energy is being lost and where the greatest savings can be made. Following the survey, we provide a clear, no-nonsense report with recommendations ranked by potential saving and return on investment.
Once you’re ready to move forward, we design, build, and commission everything in-house.
Case Studies
Discover how we’ve helped facilities like yours stay compliant across their most demanding processes.
Frequently Asked Questions
What are the key benefits of upgrading to energy-efficient printing equipment?
Upgrading to energy-efficient printing equipment delivers both immediate and long-term benefits for your operation. Modern presses and drying systems use less energy per job, helping to significantly reduce operating costs. They also improve overall efficiency, with faster start-up times, better process control, and less material waste keeping production running smoothly.
Lower energy consumption directly reduces your carbon footprint, supporting sustainability targets and strengthening your environmental credentials. At the same time, newer equipment offers greater reliability, minimising downtime and ensuring more consistent performance.
Ultimately, investing in energy-efficient technology helps future-proof your operation, keeping you compliant, competitive, and better positioned for a more sustainability-driven market.
How much of my energy bill is down to the press room vs. the rest of the facility?
Press operation and ink drying typically account for the largest share of energy use, but compressed air, HVAC, and ancillary equipment are often bigger drains than people realise. In many print facilities, compressed air alone accounts for a significant portion of total electricity consumption, and leaks and system inefficiencies mean a large proportion of that energy is wasted before it even reaches the press. Our on-site survey measures energy consumption across every part of your facility so you can see exactly where energy is wasted.
We've already upgraded our presses, is there still meaningful savings to find?
Almost always, yes. New press technology improves efficiency at the machine level, but compressed air systems, drive motors, drying and curing, and building services are frequently overlooked. These are often where the remaining savings lie, and they’re rarely addressed as part of a press upgrade.
Can energy improvements help us meet sustainability requirements?
Yes, and this is becoming increasingly urgent. Major print buyers are applying pressure on suppliers to report and reduce their Scope 3 emissions, which includes the energy used in their supply chain. Reducing your energy consumption and carbon output isn’t just a cost play; it strengthens your position with environmentally conscious clients and helps meet requirements under key frameworks.
How much can a commercial printer realistically save?
It varies depending on your size and which processes are addressed. Across our client base, businesses have achieved savings ranging from £100,000 to over £500,000 per year, typically with a return on investment of under two years.
Ensure Your Facility is Safe and Compliant
Achieve total visibility over your facility’s safety. Our precision solvent monitoring ensures you stay fully compliant while protecting your team and your throughput. Book a consultation with one of our experts to tailor a solution for your site.