UK – Terinex Flexibles has announced the opening of its new sustainable factory, rated EPC A+, and is believed to be the UK’s first net-zero CO2 building to house a flexographic printing facility.
The factory, which spans 46,000 square feet and is situated on a new 3-acre site at Dove Valley Park near Derby, will sustainably accommodate the company’s future growth and innovation plans.
The opening ceremony was led by Frank McArdle, the retired chief executive of South Derbyshire District Council, who supported OGM Holdings Group with the new-build project.
Local representatives were also present, including Dr. Justin Ives, the current chief executive of South Derbyshire District Council, and those involved in the factory’s design and construction.
The parent company, OGM Holdings Group, invested over £10 million in the new facility, which is more than double the size of the original Terinex Flexibles factory in Ripley.
As part of OGM’s focus on sustainability, the new facility, designed by IMA Architects and developed by Clowes Developments UK LTD, incorporates the latest materials, machinery, technology, and processes to minimize energy consumption and CO2 emissions.
The factory generates its energy from renewable sources. It features an innovative heat recovery system linked to an advanced regenerative thermal oxidizer (RTO), which captures and reuses energy generated during printing.
This system is expected to generate between 45 and 230 kW of energy, which will be stored as hot water in two 10,000-liter buffer vessels.
This hot water is then used to heat the air required for drying ink in the printing process and for general heating purposes, reducing the need for gas.
Additionally, the factory’s roof is equipped with a solar PV panel array with a capacity of 215 kW, which powers the factory, including 54kW immersion heaters in the buffer vessels.
Mechanical Ventilation and Heat Recovery (MVHR) systems service the offices, providing at least 75% energy-efficient ventilation.
Lighting power consumption is kept below industry benchmarks, and a night set-back system minimizes overnight heating consumption. Electric charging points are available for staff and visitors.
The building’s air permeability is no greater than 5.0 m3/ (h.m2) at 50 Pa, significantly below the minimum standard set by The Building Regulations Approved Document Part L2A of 10.0 m3/ (h.m2) at 50 Pa.
Paul Wightman, Group Managing Director of OGM Holdings Group, expressed pride in creating a state-of-the-art energy-efficient facility.
He emphasized the importance of reducing the carbon footprint of their factories by 30% by 2025 and offering more sustainable flexible film options, such as compostable, recyclable, and PCR (post-consumer recycled content) materials, compostable inks, recyclable papers, and reusable pallets.
The company also prioritizes emissions management, investing in the latest technology to ensure solvent mass emissions are below 20mg/Nm3, meeting stringent VOC emissions targets.
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