Fitesa Case Study January 18, 2012

Fitesa Case Study
January 18, 2012

� Who is Fitesa?
Case Study - Fitesa
• 11 production sites globally
• 2 nd largest Nonwoven Manufacturer in the world
• Locally - Washougal, WA since 1982
• Present Employees: 50
• Products: non-woven fabric rolls
• Fabrics composed of PP, PE, PET, PLA
• Washougal site originally designed for three energy intensive
non-woven fabric lines.
• Downsized to one retrofitted production line.
• Most of energy consumption from original lines came from air
usage.
• Energy Program evolved from capital projects to an energy
management process.
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Large
Extruders
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Spinning Pack
Face
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Production Line
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Slitting To Customer Rolls
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Case Study – Fitesa – Phase 1
� Lighting Capital Project
• Warehouse, shop, prod. areas
• Old
• Metal halides, T12 fluorescents
• 24 hours, 7 days per week
• New
• 6 & 4 lamp T8 high output, high bay
• Fixture mounted occupancy sensors
• Energy savings: 542,000 kWh/yr
• Cost savings (kWh, kW): $28,500/yr
• Project costs: $98,500
• Incentive: $34,500
• Payback: 2.2 years
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Case Study – Fitesa – Phase 1
� Compressor Capital Project
• New line required less pressure, capacity
• Baseline
• One 600 hp centrifugal
• 100 psi
• 2,500 cfm
• Blowoff valve control
• 24/7
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9

� New Compressors
Case Study - Fitesa
• New
• Two 250 hp oil free screw compressors, load - unload, lead - lag
• Energy savings: 2,000,000 kWh/yr
• Cost savings (kWh, kW): $94,000/yr
• Project costs: $490,000
• Incentive: $146,000
• Payback: 3.7 years
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Case Study – Fitesa – Phase 1
� Chilled Water Capital Project
• Retrofitted line requires less cooling capacity
• Old System
• (1) 300 hp closed loop circulation pump
• (1) 125 hp cooling tower circulation pump
• (1) 40 hp chilled water pump
• (2) cooling towers
• 10 hp fan motors
• (1) 200 ton chiller
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Closed Loop Chiller Project
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Case Study - Fitesa
� Chilled Water System
• Retrofitted line requires less cooling capacity. Went to Closed
Loop systems.
• Power reduced by ~400 hp
• Smaller pumps
• (3) 75 ton chillers
• Extensive re-piping
• Energy savings: 2,600,000 kWh/yr
• Demand savings: 300 kW/month
• Cost savings (kWh, kW): $103,600/yr
• Water, Sewer, & Chemical Savings: $140,000
• Project costs: $930,000
• Incentive: $650,000
• Payback: 1.3 years
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Case Study – Fitesa – Phase 2
• HPEM (High Performance Energy Management)
• Started Program June 17, 2010
• 5 year long continuous improvement process
• Regional collaborative effort
• Fits well with existing culture of continuous improvement
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Formation of an HPUM Team
� Form a High Performance Utilities Management Team that has representatives from all
functions in the plant.
HPUM Core Team Members
HPUM Sponsor Dave Rohrbach Plant Manager
Energy Champion JD Hisey Continuous Improvement Manager
Key Team Members Doug Moore Mechanic
Chuck Bales Electrician
Gary Jones Maintenance Supervisor
Ray Mangs Operations Manager
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Fitesa’s Global Mission and Vision
Fitesa’s Mission
Add value to Customers, Shareholders & Team by
providing high quality products with exceptional
service. We will do so by proactively reducing our
carbon foot print through better processes and product
development.
Fitesa’s Vision
Be the preferred choice for the supply of spunmelt
nonwoven fabrics in the world.
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Develop Plant Policy, Metrics, & Goals
Fitesa Washougal’s Utility Usage Policy
Fitesa Washougal will continuously look for ways to reduce our usage of
utilities so that we continue to support our environmental and cost strategies in
a way that is consistent with our global vision.
Fitesa Washougal’s Metrics
� For electrical energy, our metric is kWh/kg of saleable product produced.
� For water consumption, our metric is gallons of water purchased/kg of saleable
product produced.
� For water outfall, our metric is gallons discharged/kg of saleable product
produced.
� For natural gas, our metric is therms/day.
Fitesa Washougal’s Goals
For each element of our utility usage, Fitesa Washougal’s goal is a 5% decrease
in each metric per year.
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Create an Opportunity Register
� Meet with all plant personnel. Educate them on the mission and goals
of the HPUM Team. Ask for their ideas to reduce our carbon footprint.
.
� As a HPUM team, created initial list of utility saving ideas.
� List included all ideas. They are then prioritized.
– Some go into Project Hopper and become Capital projects for coming years.
– Most ideas will be non-capital projects. The highest priority items will be on
a Fitesa Action Plan, the rest left on the Opportunity Register.
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Example of Opportunity Register
Opportunity
#
Date Type Submitted
By
HPUM0001 7/16/10 E Shelley F.
HPUM0002 7/16/10 E Connie C.
HPUM0003 7/16/10 E Connie C.
HPUM0004 07/16/10 E Albert
HPUM0005 07/16/10 E Albert
HPUM0006 07/16/10 NG Albert
HPUM0007 07/16/10 E Tom S.
HPUM0008 07/16/10 E Steve S.
HPUM0009 07/16/10 E Tom S.
HPUM0010 07/16/10 E JD
HPUM0011 07/16/10 E JD
HPUM0012 07/16/10 E JD
HPUM0013 07/21/10 E JD
HPUM0014 07/21/10 E JD
HPUM0015 07/21/10 E JD
HPUM0016 07/22/10 W Albert
Present Situation Idea
Air Conditioners in Office - Cool at 74
degrees F, heat at 72 degrees F all
the time.
Air conditioner runs full time in the
Laminator/Documents Room
Air conditioner in the exercise room
gets left on all the time
Linde Room - Lights are on all the
time
RT Switch Room has lights on all the
time
Heater in the Surfactant room is set
for 72 degrees and control is unstable
Railcar loaders running more than
they need to
Lights are always on in the welding
shop/roll storage area
Candle Filter oven on 4th floor is on
all the time at 600 degrees.
Light in minilab on at all time. Air
conditioner set at 65 degrees F.
Lights in old foreman's office on at all
times. Air conditioner set at 65
degrees.
Many lights on at all times on 2nd,
3rd, 4th floors in old line 1 & 2 areas.
Lights on at all times in old L2 gun
bridge. Air conditioner on.
Resin dryer turned on 24 hours prior
to a PLA run, shut off at the end of
the PLA run
Pack Ovens on at 600 degrees all the
time.
Extruder for Erema kept on at full
temp at all times
Toilets and urinals are high use
designs
For offices, lower set points for cooling to 76 degrees F during
occupied times, 85degrees F for unoccupied times. For
Heating, lower to 70 degrees F for occupied times, 55 degrees
F for unoccupied times
Transfer Laminator and documents to an empty office on 2nd
floor and turn off or eliminate the air conditioner.
Install a timer switch so the air conditioner shuts off after a
period of time once activated. Ended up setting AC at 81
degrees. Shutting off would cause excessive failure of
AC.
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Repair the Motion detectors in the Linde room
Put a motion sensor in the room so that only come on as
needed or at least shut off whenever leave the room
Determine lowest set point needed for the room, then control
room to that temperature. Best temp determined to be 60
degrees. Thermostat set.
Put lights on motion detectors or a program
Implementation
Date
7/16/2010
10-Sep
18-Oct
Lower temp to 400 degrees 25-Jul
Put motion detector on lights. Lock air conditioner controls at
75 degrees.
Put motion detector on lights. Lock air conditioner controls at
75 degrees.
Remove or put motion detectors on all lights in old L1 and L2
areas. Remove all air conditioners on L1 and L2 gun bridges.
Turn on resin dryer 8 hours before a PLA run, shut off 2 hours
before end of PLA run.
Keep pack ovens at 300 degrees all the time. Turn up to 600
degrees when know will probably need to install pack. First
step completed on 9/21 to set at 500 degrees.
Turn down to 250 degrees?? if know that following shift will not
run extruder. Turn back up to full temperature when new shift
comes on board to run Erema
Install controls on Urinals and toilets so have lower flow options
24-Jul
21-Sep

Create an Energy Map
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Create Fitesa Action Plans
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Primary Tool - Conduct Energy Audits
� Nine Energy Wasters
–Unnecessary Running or Idling
–Leaks
–Pressure & Friction Losses
–Sub Optimized Efficiency
–Malfunctions
–System Imbalance
–Misapplication
–Scheduling
–Sloppy Processes (Not LEAN)
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Develop Baseline CUSUM
SUMMARY OUTPUT (6/6/09 - 6/19/10)
Regression Statistics
Multiple R 0.953579
R Square 0.909313 CV = 0.05
Adjusted R Square 0.905825
Standard Error 15851.33
Observations 55
ANOVA
df SS MS F Significance F
Regression 2 1.31E+11 6.55E+10 260.7015 7.87E-28
Residual 52 1.31E+10 2.51E+08
Total 54 1.44E+11
Coefficients Standard Error t Stat P-value Lower 95% Upper 95% Lower 95.0% Upper 95.0%
Intercept 134675.6 18994.51 7.090243 3.55E-09 96560.39 172790.9 96560.39 172790.9
X Variable 1 462.6536 39.45358 11.72653 3.21E-16 383.4842 541.823 383.4842 541.823
X Variable 2 -92141.2 24739.76 -3.72442 0.000483 -141785 -42497.3 -141785 -42497.3
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CUSUM – kWh/Kg Production
500,000
-
(500,000)
(1,000,000)
(1,500,000)
(2,000,000)
(2,500,000)
(3,000,000)
(3,500,000)
Mar-09
May-09
Jul-09
Sep-09
Nov-09
Jan-10
Mar-10
May-10
CUSUM
Jul-10
Sep-10
Nov-10
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Jan-11
Mar-11
May-11
Jul-11
Sep-11
Nov-11
Jan-12
Mar-12

Washougal Site HPUM Best Practices
Best Practices – turned into plant policy – will
help leverage best use of existing
technologies.
� Plant Lighting
– Delamp when not necessary
� Air Compressor Optimization
– Added another Receiver Tank
– Reduced from 121 psi to 112 psi
� Natural Gas Controls – Added controls in main building
� Calibration of Waste Water Outfall (Sewer) Meters
� Heating Practices
– Reduced heat up times for several operations
– Shut off several operations when not in use
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Kwh/Kg Produced
Electrical Usage - 7.6% reduction Year 1
HPUM –- 28.7% overall reduction
1.750
1.500
1.250
1.000
Electricity Usage
Kwh/kg Linear (Kwh/kg)
Month
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Natural Gas – 67.7% Reduction Year 1
HPUM
Therms/Day
200.00
180.00
160.00
140.00
120.00
100.00
80.00
60.00
40.00
20.00
0.00
Natural Gas Usage
Month
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City Water Usage - 69% reduction Year 1
HPUM
Gallons Water/MT Produced
1200
1000
800
600
400
200
0
Gallons Used/MT Produced
City Water Usage
Linear (Gallons Used/MT Produced)
Month
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Sewer Outfall – 94.6% Reduction Year 1
HPUM
Gallons Outfall/MT Produced
4500
4000
3500
3000
2500
2000
1500
1000
500
0
Gal Outflow/MT Produced
Waste Water Outfall
Linear (Gal Outflow/MT Produced)
Month
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Global HPUM Committee Created
� Fitesa facilities will strive to reduce the
amount of energy we utilize to produce our
nonwoven fabrics through efforts of best
practice sharing, trending of kpi’s and a
continuous drive for improvement.
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HPUM Committee Meeting Schedule
Sponsor: Rene Ruschel
Coordinator: Dave Rohrbach
(E) Energy
Members:
Date Time Place Brasil México Simpsonville Peru Washougal
25-Feb 1PM EST Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey
27-May 2PM ESD Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey
19-Aug 2PM ESD Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey
30-Nov 1PM EST Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey
Invited: Flavio Tavaniello, Jose Luis, Stephen Middleton
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Plant Energy Metric Review – US$/Kg
US$ / Kg
0.250
0.200
0.150
0.100
0.050
0.000
AVE10 Jan Fev Mar Abr Mai Jun Jul Ago Set Out Nov Dez
BRA 0.172 0.200 0.209 0.205 0.207 0.204 0.213 0.205 0.209 0.206 0.206 0.218 -
MEX 0.120 0.118 0.140 0.115 0.139 0.132 0.155 0.153 0.178 0.164 0.123 0.155 -
USA Washugal 0.072 0.080 0.090 0.074 0.070 0.062 0.062 0.063 0.062 0.069 0.064 0.060 -
USA Simpsonville - 0.134 0.163 0.116 0.097 0.087 0.105 0.106 0.130 0.110 0.090 0.090 -
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Plant Energy Metric Review – KWh/Kg
KWh / Kg
3.50
3.00
2.50
2.00
1.50
1.00
0.50
0.00
AVE10 Jan Fev Mar Abr Mai Jun Jul Ago Set Out Nov Dez
BRA 1.58 1.64 1.67 1.60 1.59 1.54 1.59 1.56 1.55 1.55 1.58 1.65 -
MEX 1.26 1.24 1.26 1.27 1.33 1.35 1.39 1.35 1.39 1.32 1.35 1.35 -
USA Washugal 1.27 1.35 1.51 1.23 1.27 1.10 1.11 1.14 1.11 1.11 1.05 0.98 -
USA Simpsonville - 1.81 2.41 1.62 1.86 1.53 1.68 1.63 2.06 1.74 1.42 3.22 -
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The Future – Energy Management Plan
� Short Term – Early 2012
�Add Operations Folks to HPUM Team
�Strengthen Air Leak Program
�Regular Energy Audits
�Add Controls to Natural Gas Heating in Maintenance Shop Areas
�Reduce Air Needed for Calendar Stacks and Motor Cooling
� Medium Term - 2012
�Right Size Air Dryers
�Upgrade/Reduce Exterior Lighting
�Upgrade Resin Loaders
�Expand HPUM to 6 new plants in Sweden, Germany, Italy, China and the
USA
� Long Term – 2013
�Implement Best Practices Identified at other Fitesa Plants
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