Energy Presentations

1. Mpact Plastics Atlantis
Kalev Taim – Operations Manager
14 September 2017
EnMS

2. 1
Introduction to Mpact

3. │ Presentation title │ 00 Month 201122
MPACT PLASTICS ATLANTIS
BLOWMOULDING
INJECTION MOULDING
INJECTION STRETCH BLOW MOULDING
DECORATING

4. 3
Why EnMS? Costs

5. 4
What does EnMS
now mean to
Mpact?
"When performance is measured, performance
improves. When performance is measured and
reported back, the rate of improvement
accelerates."
Thomas S. Monson

6. 5
Who?
• Management Buy-in
• It is all about return on
investment

7. 6
How to get buy-in?

8. 7
Results so far:

9. │ Presentation title │ 00 Month 201188
ENERGY MANAGEMENT SYSTEM IMPLENTATION
STEP 1 - ENERGY BALANCE
IDENTIFYING THE SEU’s
BLOWMOULDING
INJECTION MOULDING
COMPRESSED AIR SERVICES

10. │ Presentation title │ 00 Month 201199
MPACT PLASTICS ATLANTIS
ENERGY POLICY
As an energy intense manufacturer of plastic products, Mpact
Plastics Atlantis strives to reduce its energy consumption and costs
and promote the long-term environmental and economic
sustainability of its operation. We are committed to:
 Reduce energy use by 20% in 2 years across our business
operations.
 Ensure continual improvement in our energy performance.
 Deploy information and resources to achieve our energy
objectives and targets.
 Uphold legal and other requirements regarding energy.
 Consider energy performance improvements in design and
modification of our facilities, equipment, systems and processes.
 Effectively procure and utilize energy-efficient products and
services.
STEP 2 - DEVELOPING AN ENERGY POLICY,
OBJECTIVES AND TARGETS

11. │ Presentation title │ 00 Month 20111010
Step 3 – PLANNING
ESTABLISHING A ROADMAP

12. │ Presentation title │ 00 Month 20111111
STEP 4 – REGRESSION

13. │ Presentation title │ 00 Month 20111212
Target Action Leader Start Close Measurement Status
Jan-16 Feb-16 How? Frequency?
Thermal insulation of extruder barrels of plastic processing
machines [250,000KWh]
G Hardey, Q Vardan 2015/01/01 2016/06/15
Quotes
receive
d
Clamp-on
Ammeter
Before and after.
Every 2 months
thereafter
25%
50% reduction in number of light bulbs [100,00KWh] G Hardey, Q Vardan 2015/08/01 2016/03/30 Calculation Calculation 25%
Integra - Intelligient motor controllers [17,000KWh] G Hardey, K Taim 2015/07/01 2016/06/15
Clamp-on
Ammeter
Before and after.
Every 2 months
thereafter
25%
Shutdown of internal smoking area with 1kw extractor fan
[8000KWh]
Quinton Vardan 2015/06/01 2015/07/15 Calculation Calculation 100%
SWP amended to include energy. Retraining on new SWP.
[TBE]
Malusi
Mkhize/Charlotte
2015/10/31 2016/02/30 N/A N/A 50%
Job descriptions amended to add Energy. [TBE] Charmaine 2015/10/31 2016/02/12 N/A N/A 100%
Granulator management scheme [TBE] T Kotze, G Titus 2016/01/01 2016/03/15 Calculation 0%
Proactive leak detection and repair program
[250,000KWh]
T Kotze, G Titus, Q
Vardan
2015/08/01 2016/06/15 Calculation Calculation 25%
40 bar compressor management - Air dryer [TBE] G Hardey, K Taim 2015/06/01 2015/10/02 Calculation Calculation 100%
Integra - Intelligient motor controllers [160,000KWh] G Hardey, K Taim 2016/01/01 2016/06/15
Clamp-on
Ammeter
Before and after.
Every 2 months
thereafter
25%
Variable supply capacity utilisation [112,000KWh] G Hardey, K Taim 2016/01/01 2016/06/15
Clamp-on
Ammeter
Before and after.
Every 2 months
thereafter
25%
3 degree reduction in compressor air inlet temperature
[80,000KWh]
G Hardey, Q Vardan 2015/10/01 2016/12/15
Clamp-on
Ammeter
Before and after 25%
Develop SWP to include energy. Training on new SWP. [TBE] Quinton Vardan 2015/10/31 2016/02/12 N/A N/A 50%
Job descriptions amended to add Energy. [TBE] Quinton Vardan 2015/10/31 2016/02/12 N/A N/A 100%
Condensation trap monitoring program [TBE] T Kotzee, G Titus 2015/10/01 2016/04/15 Calculation Calculation 0%
Thermal insulation of extruder barrels of plastic processing
machines [250,000KWh]
G Hardey, Q Vardan 2016/01/01 2016/06/15
Clamp-on
Ammeter
Before and after.
Every 2 months
thereafter
25%
50% reduction in number of light bulbs [80,00KWh] G Hardey, Q Vardan 2015/08/01 2016/02/12 Calculation Calculation 25%
Removal of ring conveyer [40,000KWh] G Titus, G Hardey 2015/08/01 2015/08/15 Calculation Calculation 100%
SWP amended to include energy. Retraining on new SWP.
[TBE]
Quinton Vardan 2015/10/31 2016/02/30 N/A N/A 50%
Job descriptions amended to add Energy. [TBE] Quinton Vardan 2015/10/31 2016/02/12 N/A N/A 100%
Granulator management scheme T Kotzee, G Titus 2016/01/01 2016/03/15 Calculation Calculation 0%
Reduce energy consumption in
Injection moulding department
by 10% by December 2016
[130,000KWh]
Reduce the total energy consumption of the plant
Reduce energy consumption in
Blowmoulding department by
15% by December 2016
[525,000KWh]
Reduce Compressed Air
Energy Consumption by 10%
by February 2017
[250,000KWh]
STEP 5 – ACTION PLAN: There is no silver bullet

14. │ Presentation title │ 00 Month 20111313
Compressors 2015
Date
Energy
(kWh)
Driver (kg)
Expected
Energy
(kWh)
Savings
(kWh)
Jan 204,893 162,609 254,544 -49,651.21
Feb 244,159 167,251 257,215 -13,055.55
Mar 258,158 146,146 245,073 13,085.11
Apr 227,481 124,377 232,549 -5,067.94
May 220,273 157,691 251,715 -31,441.71
Jun 235,912 136,883 239,744 -3,831.56
Jul 251,362 162,324 254,380 -3,017.98
Aug 249,006 144,519 244,137 4,869.38
Sep 235,878 156,946 251,286 -15,408.09
Oct 244,867 172,311 260,126 -15,258.53
Nov 232,415 135,891 239,173 -6,758.15
Dec 175,589 79,010 206,449 -30,860.39
Blowmoulding & PET 2015
Date
Energy
(kWh)
Driver (kg)
Expected
Energy
(kWh)
Savings
(kWh)
Jan 302,614 189,589 365,204 - 62,590
Feb 391,404 216,365 388,359 3,045
Mar 387,806 190,876 366,316 21,489
Apr 332,269 153,318 333,836 - 1,567
May 364,726 179,747 356,692 8,034
Jun 378,878 168,536 346,997 31,881
Jul 409,916 189,236 364,898 45,018
Aug 396,085 186,268 362,332 33,753
Sep 398,050 196,821 371,458 26,592
Oct 426,737 221,354 392,674 34,063
Nov 380,734 159,789 339,432 41,302
Dec 252,978 111,453 297,632 - 44,654
Injection Moulding 2015
Date
Energy
(kWh)
Driver (kg)
Expected
Energy
(kWh)
Savings
(kWh)
Jan 101,316 71,764 106,940 -5,624
Feb 118,528 103,862 121,852 -3,324
Mar 74,803 59,121 101,066 -26,263
Apr 59,611 44,580 94,310 -34,699
May 70,287 55,099 99,197 -28,910
Jun 70,885 50,298 96,966 -26,081
Jul 92,129 70,543 106,372 -14,243
Aug 114,708 97,782 119,028 -4,320
Sep 128,600 112,316 125,780 2,820
Oct 123,670 110,313 124,849 -1,179
Nov 114,998 87,605 114,299 699
Dec 63,306 45,861 94,905 -31,599
STEP 6 – MONITORING OF ENPI’S

15. │ Presentation title │ 00 Month 20111414
•Savings in line with policy - YES
–“Reduce energy use by 20% in 2 years across our business
operations. “Reduce energy consumption in Injection moulding
department by 10% by December 2016” –Savings recorded in
register (in EnMS Toolkit)
•Savings have been verified?
•Future savings are planned and listed in register (Action plan in Toolkit)
STEP 7 – REVIEW

16. │ Presentation title │ 00 Month 20111515
Main Challenges
Management buy-in
Inaccurate data
Metering
Lack of understanding from energy team
Lessons learned
How to sell the idea to management
Integrate EnMS with normal management meetings
Integrate the implementation with existing systems
Training
Awareness

17. 16
Completed/ongoing Opportunities
Opportunities completed since start of program
SEU Opportunity Actual Cost Actual Savings (kWh)
Payback
(months)
Actual
Annualised
Cost Saving
Verification
Method
Applied
All Training -
behavioural
change
TBD TBD N/A TBD TBD
All Lighting -
remove bulbs
50%
R10k Lamp rating (W), number of
bulbs, hours. 157 608 kWh p.a.
N/A R157 608 Calculation
BM Intelligent motor
controllers
R25k 10kW Granulator motor 24 R12,500 Metered
Warehouse Lighting on a
schedule
0 19404 kwh p.a. N/A R19 404 Calculation
Cooling towers Thermostat R1k 84 MwH <1 month R 71,357 Metered
16