REDUCING UTILITY AND ENERGY CONSUMPTION
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1 REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES Franz Kain This report is solely for the use of Sidel Group personnel. No part of it may be circulated, quoted, or reproduced for distribution outside Sidel Group organization without its prior approval. This material was used by Sidel Group during an oral presentation; it is not a complete record of the discussion.
2 2/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
3 OUR CHALLENGE: RESOURCES SCARCITY AHEAD 3/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
4 BUT FANTASTIC POTENTIAL FOR GROWTH OF THE BEER BUSINESS World population:+ 80 Millions/ Year +3 Billion by 2050 Global population growth +1% per year Beer estimated growth +4% per year 4/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
5 SUSTAINABLE GROWTH OF THE BEER BUSINESS - Grupo Modelo The Industria Limpia and Excelencia Ambiental (Clean Industry and Environmental Excellence) recognitions awarded by the federal government through the Procuraduría Federal de Protección al Ambiente are result of our commitment. - SAB Miller - «25% reduction of Water consumption by 2015» - Heineken Our Aware of Energy programme aims to save 15 per cent energy per hectolitre (i.e. thermal energy and electricity) between 2002 and /26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
6 THE FOCUS HAS TO BE ON PACKAGING SYSTEMS Life Cycle Analysis: Indicative carbon footprint for beer packaged in a one way glass bottle Home and Disposal (8%) Distribution and Retail (13%) Factory (25%) Packaging Materials (46%) Product Raw Materials (7%) 1 6/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
7 YOU CAN MANAGE WHAT YOU CAN MEASURE Line effectiveness (OEE) measurement Energy and fluid consumption measurement Line efficiency Machine reliability Change-over Cleanings Breakages 7/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
8 ANALYSE: CORRELATING PRODUCTIVITY AND CONSUMPTION EFFICIENCY Power and fluid Consumptions OEE: overall equipment effectiveness Eco-Performance Comparison with original specifications of equipment Comparison with «best in class» values from Sidel comprehensive data base PRIORITIZED CORRECTIVE ACTION PLAN TO OPTIMIZE CONSUMPTION AND PRODUCTIVITY 8/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
9 OPTIMIZATION EXAMPLES Process analysis and optimization to reduce non-productive consumptions Before After Energies consumption Line OEE CHANGE START PRODUCTION CHANGE START PRODUCTION Optimization areas Optimized Processes 9/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
10 24/7 MONITORING SOLUTION 24 / 7 Consumption Monitoring Electricity Air Steam Water CO2 Monitoring Equipment & Auxiliaries Line / plant / multi-plant level Zone / Group of equipment Correlate with operational events What is the consumption during a CIP? What is the consumption of a product versus another? 10/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
11 MONITORING ENERGY & COSTS AT EQUIPMENT LEVEL Power Total cost of power Power cost / produced unit Power cost / equipment Power cost / motor Power consumption 11/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
12 CASE STUDIES This report is solely for the use of Sidel Group personnel. No part of it may be circulated, quoted, or reproduced for distribution outside Sidel Group organization without its prior approval. This material was used by Sidel Group during an oral presentation; it is not a complete record of the discussion.
13 60,000 BPH RETURNABLE GLASS BEER LINE 13/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
14 BEER CAN FILLER: WATER CONSUMPTION ML WATER / CAN RINSER FILLER EFFICIENCY =60 showers -40 ml/can to save with better machine setting : 2,4 m 3 /Hour -40 ml/can with increased line effectiveness = 5 m 3 /hour 14/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
15 BEER PASTEURIZER: CONSUMPTION DURING DOWNTIME Non Productive Consumption: 2,5 m 3 water 700 kg steam 15/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
16 BEER PACKAGING LINE: CORRELATION CONSUMPTION/ EFFICIENCY Efficiency Equipment Both 16/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
17 BEER CAN LINE: SHORT RETURN ON INVESTMENT Reduce equipment consumption 145 K / YEAR ENERGY SAVINGS Improve line OEE 38 K Improve efficiency 35 K 72 K 17/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
18 EXAMPLES OF IMPROVEMENTS This report is solely for the use of Sidel Group personnel. No part of it may be circulated, quoted, or reproduced for distribution outside Sidel Group organization without its prior approval. This material was used by Sidel Group during an oral presentation; it is not a complete record of the discussion.
19 NEW MACHINE LEVEL (PASTEURIZER) First System to Stop pasteurization during a build back of the pasteurizer: Use of a lot of fresh water Need Energy to reheat the pasteurizing tanks Second Generation : Mixing pumps between tanks: Reduces the need of fresh water Need Energy to reheat the pasteurizing tanks Last Generation : No more water mixing Reduces the need of fresh water Energy only to keep the hot tank at the right temperature -25% water and energy usage Improvement of PU Control thanks more performing automation platforms 19/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
20 SWING: Latest Generation of Pasteurizers sprayers sprayers STEADY CONDITION HEATING Pasteurisation tank First cooling tank sprayers sprayers PU CONTROL PHASE COOLING Pasteurisation tank First cooling tank THERMAL ENERGY SAVING UP TO 25 % 20/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
21 NEW DESIGNS AND TECHNOLOGIES Energy efficient Motors Less motors for increased accumulation Pasteurizer as Critical Machine or Flash Pasteurizer Very Compact Dry Lubrication on conveyors for One Way and Cans 21/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
22 LINE DESIGN 1. PRODUCT CARE 2. EFFICIENCY 3. TRACEABILITY 4. SPACE REQUIREMENTS LEGEND 5. ACCUMULATION SPACE RATIO 1. high pressure, bottle jam risk 2. short length, long recovery times 3. FILO (First In Last Out) m2, not compact 5. ASR: 20 % 1. average pressure 2. long length, long recovery times 3. FIFO (First In First Out) m2, not compact 5. ASR: 40 % 1. pressureless, no bottle jam risk 2. short length, short recovery times 3. FIFO (First In First Out) m 2, very compact 5. ASR: 70 % meters 22/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
23 INCREASE EFFICIENCY - 3 situations : - When filling the table : - Infeed running - Discharge stopped - End guide moving forwards - When emptying out the table - Infeed stopped - Discharge running - End guide moving backwards - When by-pass situation - Infeed running - Discharge running - End guide stopped 23/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
24 MOVIGEAR Intelligent Power solutions 3x 400V PowerLAN Supply PowerLAN 3x 400V + Bus Communication With the control command unit Movigear Movigear Movigear Sensors Sensors Sensors 24/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
25 ENERGY PLANT LEVEL Consumptions in 8 hours 85% Without water recycling Water (m 3 ) Energy (MCal) With Full recycling Water (m 3 ) Energy (MCal) Bottle Washer 122,4 0 91,8 979,2 Vacuum Pump 12, ,2 Rinsing 2, ,6 Pasteurizer 94, ,0 Crate Washer 17, ,0 Heat Exchanger 0, ,2 Total 248,5 0 91,8 2725,1 Savings % Phase 1 Phase 2 Phase 3 9 kw 12 kw 13 kw 2 25/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
26 MUCH MORE OPPORTUNITIES FOR UTILITY AND ENERGY SAVINGS High efficiency gearboxes and motors Heat recovery (Washers, Pasteurisers, etc) Colder bottle washer temperatures move from 83 C to 65 C Colder crate washer temperatures Warmer filling Cold/ambient CIP s Optimized cleaning technologies Alternative energy (Solar, windmills, hydrothermal, ) Containers Light weighting Challenge the norms & specs Etc. 26/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
27 THE FOCUS HAS TO BE ON PACKAGING Indicative carbon footprint for beer packaged in a one way glass bottle Home and Disposal (8%) Distribution and Retail (13%) Factory (25%) Packaging Materials (46%) Product Raw Materials (7%) Total = kgco 2 per 330 ml bottle SABMiller Plc /26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
28 WHY NOT A SHIFT OF PACKAGING? Life Cycle Analysis Approach 28/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
29 SUSTAINABLE GROWTH Do more with less Let s keep growing our business while protecting the natural resources 29/26 - REDUCING UTILITY AND ENERGY CONSUMPTION ON PACKAGING LINES June, 2011
30 THANK YOU This report is solely for the use of Sidel Group personnel. No part of it may be circulated, quoted, or reproduced for distribution outside Sidel Group organization without its prior approval. This material was used by Sidel Group during an oral presentation; it is not a complete record of the discussion.
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