1. 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

2. Copyright and disclaimer The Office of Environment and Heritage and the State of NSW are pleased to allow this material to be used, reproduced and adapted, provided the meaning is unchanged and its source, publisher and authorship are acknowledged. The Office of Environment and Heritage has made all reasonable effort to ensure that the contents of this document are factual and free of error. However, the State of NSW and the Office of Environment and Heritage shall not be liable for any damage which may occur in relation to any person taking action or not on the basis of this document. Office of Environment and Heritage, Department of Premier and Cabinet Phone: (02) 9995 5000 (switchboard) Email: info@environment.nsw.gov.au Website: www.environment.nsw.gov.au 2

3. Energy Efficiency through Product & Process Design Module 10 – Summary and Further Actions 3 © Australian Management Academy & Eco Products Agency

4. Why is Energy Efficiency Important? Plastics processing is energy intensive Energy use has environmental impacts Energy is a major cost for plastics processors The price of energy is increasing and will affect competitiveness Energy efficiency is a cost effective means of reducing environmental impact 4 © Australian Management Academy & Eco Products Agency

5. Life Cycle Thinking (LCT) Products have a life cycle from production through to disposal (cradle-to-grave) Environmental impacts occur throughout the life cycle Thinking through the life cycle is useful for producing lower impact products 5 © Australian Management Academy & Eco Products Agency

6. Product Life Cycle Polymer Manufacturing Polymer Manufacturing Primary Processing Primary Processing Secondary Processing Secondary Processing DIstribution Use Disposal Feedstocks Recycling Landfill Production PhaseUse Phase 6 End-of- Life © Australian Management Academy & Eco Products Agency

7. Implications of LCT 1.A large part of the energy used is determined by product design, including the materials selected and the amount required 2.Manufacturing processes can also be designed for energy efficiency 7 © Australian Management Academy & Eco Products Agency

8. Process Optimization Measure energy use in detail Analyze causes and effects Compare to benchmarks Identify key opportunities Optimize processes 8 © Australian Management Academy & Eco Products Agency

9. Process Design There are significant opportunities for energy saving through process design Process design should use a systematic approach to achieve energy efficiency Many new technologies offer energy savings 9 © Australian Management Academy & Eco Products Agency

10. Product Design Energy efficient design uses Life Cycle Thinking Materials can have more or less embodied energy Light-weighting has many energy saving benefits The effect of products on use phase and end- of-life should be considered 10 © Australian Management Academy & Eco Products Agency

11. Total Energy Saving Energy Cost $100 49% $51 Process Optimization 15% saving Process Design 15% saving Product Design 30% saving TOTAL (cumulative) 49% saving Product Design Process Design Process Optimization 11 © Australian Management Academy & Eco Products Agency

12. Most of these potential savings are ‘locked in’ at the design stage Total Energy Savings 12 82% Process Design (21%) Process Optimization (18%) Product Design (61%) © Australian Management Academy & Eco Products Agency

13. Thank you for your participation in Energy Efficiency through Product & Process Design 13 © Australian Management Academy & Eco Products Agency