This project has been assisted by the New South Wales Government through its Energy Efficiency Training Program Prepared by Energy Efficiency through Product & Process Design Prepared by Plastics Industry Manufacturers of Australia (PIMA) in partnership with Australian Management Academy (AMA); executed in collaboration with EcoProducts

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Energy Efficiency through Product & Process Design Module 7 – Energy Efficient Manufacturing Process Optimisation 3 © Australian Management Academy & Eco Products Agency

Key Points 1.Where is energy used in manufacturing? 2.Measuring energy use 3.Analyzing energy use 4.Benchmarking 5.Process optimization 4 © Australian Management Academy & Eco Products Agency

Energy Efficiency Measure –Understand your energy use –Compare with benchmarks –Identify opportunities for energy saving 5 © Australian Management Academy & Eco Products Agency

Energy Use Key energy uses in plastics processing are: –Drying materials prior to processing –Heating materials up to the processing temperature –Cooling products after processing –Building services Heating, cooling, lighting –Ancillaries Compressors, granulators 6 © Australian Management Academy & Eco Products Agency

Energy Use Energy use in a typical injection moulding plant 7 © Australian Management Academy & Eco Products Agency

Energy Use Measuring energy use –Electricity and gas bills –Sub-metering by area or machine –Short term monitoring of key equipment –Estimate % on-time x power rating x duty factor Analysis –By plant production volume –By process 8 © Australian Management Academy & Eco Products Agency

Energy Use by Production Volume 9 © Australian Management Academy & Eco Products Agency

Energy Use by Production Volume 10 Process Characteristic Line (PCL) Base Load © Australian Management Academy & Eco Products Agency

Energy Use by Production Volume Base load should be <30% of max load, preferably <10% Scatter indicates potential waste Investigate variances and trends 11 © Australian Management Academy & Eco Products Agency

Energy Use by Process Energy use in a process or process line can be characterized by the Specific Energy Consumption (SEC) Unit of material is usually kg or tonne But could also be number of parts 12 © Australian Management Academy & Eco Products Agency

Energy Use by Process 13 © Australian Management Academy & Eco Products Agency

Energy Use by Process Larger throughputs are more energy efficient –Less waste heat –Lower drive losses Injection & blow moulding have higher SEC –energy for opening and closing tools and other actions 14 © Australian Management Academy & Eco Products Agency

Benchmarking Compare SEC with best practice for similar processes and throughputs May be misleading due to: –Different types of products –Different size operations Benchmark like-for-like if possible Internal benchmarking of similar operations can be powerful 15 © Australian Management Academy & Eco Products Agency

Benchmarking Typical energy use for plastics processing 16 © Australian Management Academy & Eco Products Agency

Summary The use of simple financial tools enables comparison of costs and benefits for energy efficiency investments No single financial tool is best for all uses Non-financial benefits should also be considered when assessing options 17 © Australian Management Academy & Eco Products Agency

Energy Management Manage energy as carefully as labour Startup and shut down procedures Job scheduling to avoid running equipment that is not in use –Dryers –Granulators –Moulding machines –Lights 18 © Australian Management Academy & Eco Products Agency

Adjusting Process Conditions Process temperatures as low as possible Cycle times and rates as high as possible Cooling water temperatures no lower than necessary Minimize rejects 19 © Australian Management Academy & Eco Products Agency

Maintenance Eliminate compressed air leaks Insulate cold water lines Minimize downtime Minimize rejects 20 © Australian Management Academy & Eco Products Agency

Summary Understand where energy is being used Measure energy use in detail Analyze by production volume and SEC Compare to benchmarks Identify key opportunities Process Optimization 21 © Australian Management Academy & Eco Products Agency