objective
Conduct energy, water and waste assessments across the manufacturing facility and identify potential no/low-cost and CAPEX projects including associated savings. Following assessment completion, conduct engineering studies to develop solutions including business case development, paybacks and technical drawings
Client Situation
Like so many large-scale manufacturers in South Africa, the client is exposed on a daily basis to risks pertaining to secure energy supply from Eskom. While efforts were underway to improve energy efficiency across its site, allocating necessary resources and time to implement and monitor projects aimed at improving efficiency across the plant was stumbling block.
Subsequently a resource efficiency programme was developed to identify no/low-cost energy solutions as well as longer-term more CAPEX driven solutions. Concurrently, elements of an Energy Management System would be implemented including data monitoring, dashboard development and long-term target setting. In addition, and to ensure that the programme was holistic in nature, focus was also given on ways to improve the consumption of water within the manufacturing process as well as ways to diminish the generation - and optimise the use of - waste streams generated on site.
Our Approach
Following completion of the assessment, a number of focus areas emerged where significant savings could be achieved. This were in the areas of waste heat recovery, compressed air management, water recycling and reuse and data management.
A Steering Committee was established to provide monthly updates to Senior Management as well as convey progress on status of engineering studies. Each focus area was allocated an internal Project Champion who provided technical input to the TEPM team.
Subsequently, detailed engineering studies were conducted which included, but was not limited to:
- Required design work;
- Updating of technical drawings; and
- Engagement and coordination of specialists where necessary for all opportunities.
On-going data collection for all opportunities was also conducted to establish a baseline for savings as well as reaffirm assumptions made during assessment phase.
Finally, CAPEX requirements and business cases were pulled together and presented to the Steering Committee and Senior Management.
Client Impact
Opportunities exceeding R10m in savings were identified with a cumulative payback of under 24 months. Resource efficiency became integrated into management dashboards. Certain low-cost opportunities were implemented during the engineering studies with larger projects earmarked for implementation during summer shutdown.