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Kalev Taim Mpact Atlantis EnMS Presentation Century City

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Kalev Taim Mpact Atlantis EnMS Presentation Century City

  1. 1. Mpact Plastics Atlantis Kalev Taim – Operations Manager 14 September 2017 EnMS
  2. 2. 1 Introduction to Mpact
  3. 3. │ Presentation title │ 00 Month 201122 MPACT PLASTICS ATLANTIS BLOWMOULDING INJECTION MOULDING INJECTION STRETCH BLOW MOULDING DECORATING
  4. 4. 3 Why EnMS? Costs
  5. 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. 6. 5 Who? • Management Buy-in • It is all about return on investment
  7. 7. 6 How to get buy-in?
  8. 8. 7 Results so far:
  9. 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. 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. 11. │ Presentation title │ 00 Month 20111010 Step 3 – PLANNING ESTABLISHING A ROADMAP
  12. 12. │ Presentation title │ 00 Month 20111111 STEP 4 – REGRESSION
  13. 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. 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. 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. 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. 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

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