Implementation of the EMS, experiences

Energy management implementation, experiences in the participating countries

Energy management is nowadays a subject that is inseparable linked to every company. Through an Energy Management System, companies are helped to meet the objective (or legal regulations) to comply with energy efficiency and savings with the aim of actively reduction of greenhouse gas. In the print media industrie more and more companies show serious interest for this subject.

From the EMSPI-project there are a total of 110 notifications to participate in the implementation of ISO 50001. Companies had in some participating one and in other countries more workshops for the implementation of the Energy Management System according to the ISO 50001:2011.

Experiences in Czech Republic

Printing companies were especially interested in concrete energy efficiency measures that they could undertake in order to save energy and money. The team proposed specific measures for each printing company individually and these will be proposed in the action plan that will be part of the energy management system.

Typical measures that were identified are the following:

- Replacement of lighting (examples specific recommendations for companies)

Replacement of the existing fluorescent lamps in the production area for LED fluorescent lighting was proposed in one company. This area is currently illuminated with 48 pieces of double tubular fluorescent lamps with an output of 58 W / tube. And the lights are on for 4,000 hours per year. The project team made a calculation based on a replacement piece by piece (before carrying out they investment a light-technical calculation needs to be made where the total number of tubes could be larger or smaller).

The electricity savings are calculated at 10 MWh/year. At an energy price of 2115 CZK/MWh the annual cost savings will be 22,000 CZK/year. The investment is estimated at 100 000 CZK, meaning an approximate return on investments of 4.7 years. At another printing company, replacing the fluorescent lamps in the area of the printing machines was also considered. The existing lamps had slightly different but comparable parameters, leading to an estimated return on investment of 4.3 years. In a smaller printing company, where they considered the same measure, the rerun on investment was more than 6 years. The longer pay-back period here was caused by the lower number of lighting hours per year, leading to less energy savings.

These examples show that such a standard measure may have different savings and pay back times depending on the specifics of the company, such as the no. of hours that the lights are on during the year. 

- Utilisation of waste heat

Utilization of waste heat was proposed for heating the administrative part of one mid-size printing company. Installing fans that will blow warm air from the plant floor to the space administration, suppresses the dependence of heating the administrative section for heating the production hall. The reason for the regulation of heat supply gas boiler depending on the internal temperature of the production hall, which is located central thermostat.

The measure leads to a small increase in electricity consumption, which is compensated with a large decrease in gas consumption. The return on investment of the measure at current electricity and gas prices is only 2.3 years.

Another proposed measure, leading to the use of waste heat from the compressor for hot air heating in the commercial department. This is a project with similar results, but due to the higher upfront investments, the return on investments is almost 6 years.

Also here we see different numbers per company.

Experiences in The Netherlands

Energy management is nowadays a subject that is inseparable linked to every company. Through an Energy Management System, companies are helped to meet the objective (of legal) to comply with energy efficiency and savings with the aim of actively reduction of greenhouse gas. In the print media Industrie more and more companies show serious interest here for.

From the EMSPI-project there are a total of 30 notifications to participate in the implementation of ISO 50001. Companies had at least four workshops for the implementation of the Energy Management System according to the ISO 50001:2011.

In addition to the workshops, there were visits on locations, in order to note to what level energy management within the business is actually carried out. It was striking how many companies still were surprised with the amount of work required for the realisation of the objectives for EMSPI-project. That was not all to the adaption work of the developed blueprint material to their own business operations, but a major task was to gather the right energy data. Collecting energy data turned out to be the real challenge. Especially for smaller companies, which until recently, did nothing with energy monitoring. For the big companies it seemed something simpler since they keep track of energy data from the legal framework.

A final meeting with participating companies was organized. At the meeting, the interim results, based of all data collected, were presented. On the positive side, the target for energy savings achieved are good. As regards the potential CO2 reduction the result so far to call itself particularly well: the goal was 880 tons of CO2 reduction per year and it seems to be heading for more than 3,000 tons. The companies found this a good result and eventually see in practice how the effort over the last few months results in a success.

In addition presenting the results, in the meeting experiences were exchanged. The energy managers of the participating companies indicated  they would like more information about the payback periods of investments (ROI). To teach the goals technical improvements can be necessary. The financial part of it is also very important. On the other side companies indicated that if many energy saving measures were implemented, it was no longer certain that some more savings could be achieved. Taking part in the EMSPI project made sure for internal increase in energy awareness among colleagues and the topic ‘Energy’ is back on the boardroom making it again as a serious management issue.

From the evaluation of the implementation process, it appears most of the companies were satisfied with the EMSPI-developed material. It appears a large amount of participants are satisfied or very satisfied with the support throughout the implementation project. The participating companies also give clearly they actually expect to achieve energy reduction and will – by the pragmatic approach – recommend the EMSPI material to fellow companies.

We can therefore conclude that the EMSPI project is on its way to be successful. That success has been achieved by the good contribution  of the participating companies.

 

Experiences in Denmark

The project Energy Management Standardization in Printing Industry (EMSPI) was by the end of 2015 changed into the phase of implementation in the Danish printing companies. Workshops have been carried out focusing first on an introduction to energy management and followed by training of the printing companies in working with energy management and improving the energy performance.  

In total 20 Danish companies are participating in the EMSPI project and have started the continual process of working with energy efficiency at the strategic level as well as the operational level of the company. The participating companies have shown great enthusiasm working with the developed tools and guidelines. 

In all participating companies the energy consumption as well as the potentials for energy savings have been mapped and analysed and the companies have started the process of setting specific targets and making action plans. In some companies the first energy improvement project have already been carried out while in other companies the projects are planned to be carried out during 2016 and 2017. 

The experiences from the participating Danish companies show five primary areas for improvements:

1.     Compressed air

2.     Ventilation

3.     Lighting

4.     Heating system

5.     Production machines

 

Experiences in Spain

Energy efficiency has been acquiring a more important role in Spain throughout the years. This is mainly due to the current national situation of political and economic instability. This situation that affects directly to the energy sector, makes energy efficiency one of the most safer values when designing saving measures by the Spanish Companies. A number of 21 Companies, with the assistance from the specialized international firm Factor, have developed an analysis of their sources and energy consumption, which allows them to design a series of energy measures to reduce their energy consumption. In order to standardize and to continue with the energy plan, they are concluding with the implementation of an Energy Management System based on the ISO 50001 standard adapted to the Industry.

The Spanish companies have reduced the main KPI of the project (GJ total energy / ton paper) from 1,3 to 1,1. As a consequence, they have reduced considerably their CO2e emissions in paper consumption, electricity and waste treatment since 2013 (893 tCO2e), incorporating measures in lighting, insulation and efficient machines, among others. However, the companies are in the process of developing a new package of measures in order to reduce their consumption over the next few years. 

Energy efficiency has been acquiring a more important role in Spain throughout the years. This is mainly due to the current national situation of political and economic instability. This situation that affects directly to the energy sector, makes energy efficiency one of the most safer values when designing saving measures by the Spanish Companies. A number of 21 Companies, with the assistance from the specialized international firm Factor, have developed an analysis of their sources and energy consumption, which allows them to design a series of energy measures to reduce their energy consumption. In order to standardize and to continue with the energy plan, they are concluding with the implementation of an Energy Management System based on the ISO 50001 standard adapted to the Industry.

The Spanish companies have reduced the main KPI of the project (GJ total energy / ton paper) from 1,3 to 1,1. As a consequence, they have reduced considerably their CO2e emissions in paper consumption, electricity and waste treatment since 2013 (893 tCO2e), incorporating measures in lighting, insulation and efficient machines, among others. However, the companies are in the process of developing a new package of measures in order to reduce their consumption over the next few years.

 

 
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