Annual Report 2009 - Plastics New Zealand

Best practice
energy
Simon Wilkinson
Best Practice Facilitator
Plastics NZ
simon@plastics.org.nz
Our Best Practice Energy Programme
continues to grow and improve. The
programme delivers environmental benefits
as well as saving money for Plastics New
Zealand member companies.
Since the beginning of 2007 we have run
comprehensive energy audits at 18 plastics
manufacturing sites. These sites have a
combined energy use of 64.2 gigawatt hours
(GWh) costing $6.8 million per annum. The
Best Practice Energy programme audits
have identified potential energy savings
of 7 GWh (11%) and financial savings of
$900,000 (13%).
As of December 2008, the 18 companies
had actually implemented 2.1 GWH of
energy savings and $325,000 of annual
cost reductions.
Audits Completed 18
Total Annual Energy Use 64,203,316 kWh $6,816,736
Total Savings Identified 6,992,707 kWh $905,175
Average % Savings 11% 13%
Savings Implemented to date 2,103,174 kWh $324,898
Carbon emissions reduction
1,119 tonnes
We have also developed a plastics industry
energy benchmarking tool. This online tool
allows PNZ member companies to track their
energy data over time and compare their
performance against European benchmark
data. The tool is simple to use and completely
confidential – users create their own unique
username and password. The tool can be
found at http://benchmark.plastics.org.nz/
There is a negative perception within the
plastics industry about the use of insulation
on moulders and extruders. We have been
successful in obtaining funding to trial barrel
and die insulation on machines at four PNZ
members’ sites. A fire risk assessment
has been conducted by AON insurance
company and this assessment found no
potential fire risk from the insulation jackets.
We will be monitoring the energy efficiency
potential from using these insulation jackets,
observing any production issues that arise,
and disseminating the results to the industry
so you can judge the worth of insulation for
yourselves. Two Best Practice Energy case
studies have been completed and a third is
close to publication. The case studies are:
1. Compressed Air
2. What’s Involved in an
Energy Audit
3. Energy Efficient
Water Cooling
Compressed air
uses up to 40%
of the electricity
in a plastic
factory, yet it
only delivers
10-15% of the
energy it uses.
COMPRESSED AIR
expensive but easy to control
Energy audits of the New Zealand plastics
industry in 2 07 and 2 08 have found
that injection moulding companies use
betw en 5-5% of their total electricity on
compre sed air. Pipe/profile extruders and
thermoforming companies use 20-40% of
their electricity on compre sed air.
This guide contains three simple steps to
reducing compre sed air costs on your site.
www.plastics.org.nz
Plastics company saves $40,000
in compressed air
A New Zealand plastics manufacturer has found that compre sed air
represents 38% of their a nual energy bi l - a cost of $120,0 0 p.a.
The company is able to save $40, 0 of these a nual costs by fixing air leaks,
reducing the pre sure set point, and by using electric blowers rather than
compre sed air in some areas.
Three Steps to Compressed Air Efficiency:
Reduce
Optimise Continual
1 Demand
2 Supply
3 Improvement
Maximising the growth and su ce s
of plastics-based technology in New
Zealand in an economica ly, socia ly and
environmenta ly responsible ma ner.
All are downloadable
from www.plastics.org.nz or drop us a line
and we will post a hard copy to you.
In November the Energy Efficiency and
Conservation Authority (EECA) board
approved our proposed Best Practice
Energy programme that will take us through
to the end of 2010. This is a real feather
in Plastics New Zealand’s cap as it is the
first time EECA have funded a programme
across two financial years. It shows the
trust they have in Plastics New Zealand to
deliver results.
Key components of the programme that we
will be delivering over the next 2 years are:
1. Energy Audits for Large Companies
Deliver 12 comprehensive energy audits
to PNZ members and assist them to
implement energy saving opportunities.
2. Low-cost Audits for Small Companies
Deliver 20 energy audits to companies
with an energy spend below $100,000
per annum. These audits will cost the
companies just $500.
3. Provide Onsite Training for Technical
Staff
As we deliver the findings of energy audits
we will also provide technical training to
company staff in energy efficiency in a
plastics manufacturing plant. Training
will be practical and aim to provide key
staff with the skills to improve energy
efficiency on an ongoing basis.
4. Development of Training Unit
Standards
We will scope out the opportunity to
integrate energy efficiency into existing
training units, or create a stand-alone
energy efficiency module.
5. Energy Efficient Technology Updates
We have funding for a person to attend
NPE Chicago in 2009 and K-Fair in 2010.
The person will have expertise in plastics
processing plant and a knowledge
of energy efficiency. They will review
all new energy efficient technology at
these expos and return to New Zealand
to deliver a series of seminars to PNZ
members advising them of the latest
technologies and their true applicability.
6. Best Practice Case Studies
We will produce four more case studies
of energy efficiency best practice in the
plastics industry.
ANNUAL REPORT 2009
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24
PLASTICS NEW ZEALAND
ENVIRONMENTAL ACTIVITY