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

2. Introduction to Mpact

3. MPACT PLASTICS ATLANTIS
BLOWMOULDING INJECTION MOULDING INJECTION STRETCH BLOW MOULDING DECORATING

4. 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

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

7. 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

8. Results so far:

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

10. 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.

11. ESTABLISHING A ROADMAP
Step 3 – PLANNING
ESTABLISHING A ROADMAP

12. STEP 4 – REGRESSION

13. 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.

14. 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
,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
,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
,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.

15. 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)

16. 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. 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 kWh p.a. R
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.