PCS has used its KBA Genius 52 UV press to produce 2m Coop DanmarkPlus loyalty cards using biodegradeable polymers supplied by Gallazzi Spa, and waterless print technology in what it claims is a UK first.

Rob Nicholls, managing director at Macclesfield-based, £5m-turnover PCS, said: "While the material for the Coop's biodegradable plastic loyalty card is market available, we are manufacturing the material together with all the environmental benefits of waterless litho."

"A lot of R&D has gone into the product, and it has been specifically developed for this project with the Coop."

The Genius 52 UV is a standardised sheetfed offset press with waterless and UV technology.

It can print up to 8,000 sheets per hour in a size of 360mmx520mm, and complete a plate change within five minutes, with around 10 sheets of run-up waste. 

Nicholls added that the 68-staff business has had to meet strict environmental credentials to make the product, and plans to convert 50% of its business to biodegradeable materials in the next five years.

The bioPVC material is designed to decompose in less than three years, in comparison with the conventional 300-1,000 year cycle for PVC.

Using a waterless print process "significantly reduces emissions or harmful compounds into the atmosphere", according to the business.

Nicholls said: "The Scandinavian countries are early adopters, and the UK is starting to follow suit. The B3 KBA Genius 52 UV press more than keeps up with production and we chose it for this specific purpose.

"It addresses all the environmental points, as well as helping to reduce our waste and carbon footprint. There is no waste water, no alcohol used and minimal VOCs ."

The loyalty cards have been distributed from the company's Macclesfield manufacturing site to households across Denmark in the country’s largest ever loyalty scheme.

A spokesman for KBA said: "It is the first time that major users of cards have taken on a biodegradable product, which may indicate the future of these products.

"The press is a B3-format press, and while many people think that the most economical press is B2, the B3 actually gives better accuracy and reduces excess waste with a much more vibrant ink quality."

PCS produces more than 50m cards a year for household names across the UK including Next, Virgin, Ikea, Ford, Iceland and npower.