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

Introduction to Mpact

MPACT PLASTICS ATLANTIS BLOWMOULDING INJECTION MOULDING INJECTION STRETCH BLOW MOULDING DECORATING

9/11/2018 Why EnMS? Costs What are the cost trands? RM down due to light weighting, Labour Down due to automation, Electricity up. All of these costs we know the exact breakdown, except electricity

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

Who? Management Buy-in It is all about return on investment

How to get buy-in? Example of motivations for Capex, Cake example 9/11/2018 How to get buy-in? Example of motivations for Capex, Cake example

Results so far:

ENERGY MANAGEMENT SYSTEM IMPLENTATION STEP 1 - ENERGY BALANCE IDENTIFYING THE SEU’s BLOWMOULDING INJECTION MOULDING COMPRESSED AIR SERVICES

STEP 2 - DEVELOPING AN ENERGY POLICY, OBJECTIVES AND TARGETS 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.

ESTABLISHING A ROADMAP Step 3 – PLANNING ESTABLISHING A ROADMAP

STEP 4 – REGRESSION

STEP 5 – ACTION PLAN: There is no silver bullet You can here these presentations, and many times there is a silver bullet approach to achieve amazing results, reality is that is not what an EnMS is about.

STEP 6 – MONITORING OF ENPI’S 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 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 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 Report energy usage in our daily production meetings after meters have been installed.

STEP 7 – REVIEW 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)

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

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 N/A Lighting - remove bulbs 50% R10k Lamp rating (W), number of bulbs, hours. 157 608 kWh p.a. R157 608 Calculation BM Intelligent motor controllers R25k 10kW Granulator motor 24 R12,500 Metered Warehouse Lighting on a schedule 19404 kwh p.a. R19 404  Cooling towers Thermostat R1k  84 MwH  <1 month R 71,357   Metered Insert a table listing opportunities complete since the start of this program. For each include the title, SEU, actual kWh savings and payback.