Annual Report 2009 - Plastics New Zealand

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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 I 24 PLASTICS NEW ZEALAND ENVIRONMENTAL ACTIVITY
7. Development of a Hopper Dryer Heat Exchanger We will also be working at the Plastics Centre of Excellence on the development of a prototype heat exchanger for resin hopper dryers. This technology has potentially wide applicability throughout the industry. If you are interested in more information about any part of this programme, or if you would like an energy audit of your site please contact Simon Wilkinson, Best Practice Programme Coordinator on 021 944 992 or email simon@plastics.org.nz n $10 Million contestable waste levy fund Under the Waste Minimisation (Solid) Act 2008 there be a national waste levy of $10 per tonne (excl. GST). It will come into force in July 2009 and generate $30 million per year. Half will be available to councils and the remainder (less administration) will be a contestable fund of over $10 million per year. Plastics New Zealand will be well placed to apply for this funding n Packaging Accord and negotiations for the third Accord By the end of the year two meetings will have been held to discuss how the packaging sectors want to progress the third Packaging Accord. The general sentiment from the packaging sectors and the Packaging Council is that we want to a voluntary packaging product stewardship scheme accredited by the Ministry for the Environment. There is a strong preference for a voluntary rather than mandatory scheme. The new Accord will require funding from the brand owners and importers and the setting of challenging targets for the recovery of plastic. The Ministry for the Environment will be consulting on the list of priority products that will be required to have a mandatory product stewardship scheme. A report is expected in March 2009. ENVIRONMENTAL ACTIVITY Target 23% by 2008 – we reached the target in 2007. To remain on target, given increasing plastic packaging consumption, we need to recover an additional 4,000 tonnes each year. in the 2007 calendar year we reached the target of 23%. Current and Projected Consumption and Recycling of Plastic Packaging in NZ Year Consumed Recovered 2000 117,475 20,809 18 2001 128,985 23,758 18 2002 123,485 23,305 19 2003 125,955 23,816 19 2004 137,909 28,004 20 2005 145,650 31,310 21 2006 156,359 34,891 22 2007 147,616 33,770 23 How do we compare to Europe New Zealand’s plastic packaging recovery rates compare well with Europe. We are up there with Scandinavia and much of Central Europe. For all plastic recovery New Zealand is well under 20% recovery. You will also notice that the countries with the highest energy recovery percentages also have the higher recycling percentages indicating there is a synergy between the two. Now that energy recovery and composting are recognised as recovery in the European Waste Directive, PNZ will aim for the same recognition in the third NZ Packaging Accord. Belgium expert on plastic packaging recycling in Europe An Vossen, Manager, Plarebel visited NZ in November and give an excellent presentation on plastic recycling in Europe and future trends. We took her to Waiheke Island to look at a community recycling scheme. She was impressed with the quality of their products. An’s presentation was really well received by the industry people who attended. She had graphs showing recycling commodity prices for resins as well as very timely information on plastic packaging recycling rates on Europe. Her key recommendation was that quality product give flexibility and always finds a market, even during the low part of the commodity cycle. An works for Plarebel [see http://www.eproplasticsrecycling.org/c_19_1.html], a nonprofit organisation which is a member of the EPRO [European Association of Plastic Recyclers and Recovery Organisations]. Plarebel promotes the recycling of all plastic waste, but mainly acts as an expertise centre for FOST Plus with regard to the organisation of the collection and sorting, the recycling technologies, the material specifications, etc. for the different types of household plastic packaging waste, regular contacts with and visits to sorting centres and recycling companies contribute to an efficient implementation of the recycling activities n ANNUAL REPORT 2009 PLASTICS NEW ZEALAND I 25
Page 1 and 2: Annual Report 2009 Maximising the g
Page 3 and 4: National President’s Statement Te
Page 5 and 6: Ken Sowman: Group Operations Manage
Page 7 and 8: CEO Report 2008 was another very bu
Page 9 and 10: Membership Services Young Designers
Page 11 and 12: Gold Award Winners Kaynemaile: Rewa
Page 13 and 14: with local engineering companies co
Page 15 and 16: We can now go forward with confiden
Page 17 and 18: Plastics Centre of Excellence Len H
Page 19 and 20: Industrial Relations Nigel Donne (M
Page 21 and 22: Environmental Matters Introduction
Page 23: Area of activity Iconic Kiwi Plasti
Page 27 and 28: Life Members * H C URLWIN AND H.L L

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