The document describes an ECOPROFIT conference in Cape Town that aims to improve manufacturing resource efficiency in the Eastern Cape. It outlines the conference's target groups, objectives, and approach of assisted peer learning and identifying low-cost efficiency improvements. The approach uses a methodical process and ISO-compatible tools to review resource use, develop and implement efficiency measures, and establish monitoring. Participating companies implemented measures like optimizing compressor use, fixing leaks, and lighting upgrades, saving over 300,000 kWh and R311,550 annually. Lessons highlighted group learning and keeping materials simple and focused on resource monitoring.

1. NCPC-SA Industrial Efficiency
Conference 2017
Cape Town
14 September
Improving Resource Efficiency in the
Manufacturing Sector in the Eastern Cape

2. Idea and Approach
– Target group: SMMEs + champion companies that share
and attract
– Main objective: low hanging fruits + awareness creation
– Main approach: assisted peer learning
– ECOPROFT: methodical process to increase resource
efficiency and thus save money and protect the
environment via:
• reviewing resource efficiency in manufacturing
• developing evaluating, implementing and reviewing measures
that increase resource efficiency and reduce costs
• using tools consistent with ISO management systems
2

3. Elements
– thematic workshop: basic information
– individual company on-site visits: identification of
potential measures
– working material that is ISO 14001/50001 compatible
and visit protocols
-> identification of measures based on cost-benefit-
analyses
-> implementing monitoring system
-> Networking and peer learning
3

4. 4
Structure

5. 5
A 3-1 Energy-Inputs/CO2-Emissions
A 3-2 Significant Energy Uses (SEUs)
A 3-3 Compressed Air
A 3-4 Ventilation and Air-Conditioning
A 3-5 Refrigeration
A 3-6 IT and Workstations
A 3-7 Lighting
A 3-8 Machines, Motors and Drives
A 3-9 Heat Generation
A 3-10 Measurement Concept
A 3-11 Monthly Energy Input
Worksheets table of content

6. MAP of Participating companies
6

7. 7
Company Measure Saving in
kWh/a
Cost Savings in
ZAR/a
Implementatio
n Cost in ZAR
Payback period
Autopipe Switching off compressor at night 80,000 54,000 0 immediately
Fixing compressed air leakages 22,000 15,000 15,000 1 year
Switching parts washer to blower 2,000 150 0 < 1 year
Isri Repair and upgrade of heat pumps 28,000 19,000 ?? < 3 years
Reduction of temperature in degreasing
tank
2,000 1,400 0 < 1 year
Testing of powder paint with lower curing
temperatures
To be
assessed
0 < 1 year
Prism Suggested use of removal barrel insulation
blankets on five machines
75,000 51,000 50,000 < 1 year
Suggested retrofit of VSDs on three
machines
90,000 61,000 150,000 < 3 years
Repair of air leaks 24,000 16,000 0 immediate
Installation of motion detectors in sanitary
units
500 400 400 1 year
Yenza Optimizing operating time of compressor 40,000 52,000 0 immediately
Fixing compressed air leakages 20,000 26,000 2,000 < 1 year
Removing/replacing broken fluorescent
tubes
12,000 15,600 10,000 < 1 year
Sum 395,500 311,550 227,400

8. Yenza Manufacturing Port Elizabeth
– established in 1997 and employs 15 people
– spinning and pressing stainless steel components
for Tier 1+2 companies of the automotive industry
by spot and robotic welding and assembly
8

9. Yenza Manufacturing Port Elizabeth
– 60 broken but yet glowing fluorescent tubes were
replaced or switched off
-> 7,000 kWh/a
– Air leakages have been detected, new regulators,
clamps and fittings have been installed
– 55 kW screw compressor was running at very low load
of 39 %.
– compressor is now switched off completely during
nights and week ends
-> 59,600 kWh/a
9

10. Case Study 3
– …
10

11. Case Study 3
– …
11

12. Case Study 3
– …
12

13. Yenza Manufacturing Port Elizabeth
– …
13

14. Yenza Manufacturing Port Elizabeth
– …
14

15. Yenza Manufacturing Port Elizabeth
15
ECOPROFIT savings measures
Measure Annual
Resource
Saving
Annual Cost
Saving
Implementati
on Cost
Payback
period
Optimizing operating
time of compressor
40,000 kWh R 52,000 R 0 immediat
ely
Fixing compressed
air leakages
20,000 kWh R 26,000 R 2,000 < 1 year
Removing/replacing
broken fluorescent
tubes
12,000 kWh R 15,600 R 10,000 < 1 year

16. Yenza Manufacturing Port Elizabeth
“Ecoprofit has been successful project for us. It has
been a first step towards our ISO 14001
certification.“
Themba Mtati
16

17. Lessons learned
– Better together: Group setting leads to exchange
and generation of ideas and ensure lasting effect
– Keep it short and simple: Work material has to be
simple and adjustable
– No sweet without sweat: Investing time in resource
monitoring requires convincing
17

18. For further information please contact:
Dr Maik Winges
maik.winges@giz.de
082 950 6264
Thank you very much!

19. Worksheets
19
A 3-1 Energy-Inputs/CO2-Emissions
A 3-2 Significant Energy Uses (SEUs)
A 3-3 Compressed Air
A 3-4 Ventilation and Air-Conditioning
A 3-5 Refrigeration
A 3-6 IT and Workstations
A 3-7 Lighting
A 3-8 Machines, Motors and Drives
A 3-9 Heat Generation
A 3-10 Measurement Concept
A 3-11 Monthly Energy Input
Worksheets table of content

20. Worksheets
20
Company:
Use
Rated Power
[kW]
Average load
factor [%]
Hours/ Day Days/ Year Hours/ Year
Consumption
[kWh/ a]
Share of Total
Electricity uses
Compressed Air 60% 0 0 #DIV/0!
Ventilation and Air Conditioning 40% 0 0 #DIV/0!
Refrigeration 70% 0 0 #DIV/0!
IT and servers 50% 0 0 #DIV/0!
Lighting 100% 0 0 #DIV/0!
Workstations 30% 0 0 #DIV/0!
Machines 70% 0 0 #DIV/0!
Kitchen/ Canteen 80% 0 0 #DIV/0!
Heating pumps 40% 0 0 #DIV/0!
Electrical motors and drives 70% 0 0 #DIV/0!
0 0 #DIV/0!
0 0 #DIV/0!
Significant Energy Uses (SEUs) ECOPROFIT Date:
Author: Version: