Cross Cutting Presentations

1. NCPC-SA Industrial Efficiency
Conference 2017
Cape Town
14 September
Improving Resource Efficiency in the
Manufacturing Sector in the Eastern Cape

2. Idea and Approach
– Target group: SMMEs + champion companies that share
and attract
– Main objective: low hanging fruits + awareness creation
– Main approach: assisted peer learning
– ECOPROFT: methodical process to increase resource
efficiency and thus save money and protect the
environment via:
• reviewing resource efficiency in manufacturing
• developing evaluating, implementing and reviewing measures
that increase resource efficiency and reduce costs
• using tools consistent with ISO management systems
2

3. Elements
– thematic workshop: basic information
– individual company on-site visits: identification of
potential measures
– working material that is ISO 14001/50001 compatible
and visit protocols
-> identification of measures based on cost-benefit-
analyses
-> implementing monitoring system
-> Networking and peer learning
3

4. 4
Structure

5. 5
A 3-1 Energy-Inputs/CO2-Emissions
A 3-2 Significant Energy Uses (SEUs)
A 3-3 Compressed Air
A 3-4 Ventilation and Air-Conditioning
A 3-5 Refrigeration
A 3-6 IT and Workstations
A 3-7 Lighting
A 3-8 Machines, Motors and Drives
A 3-9 Heat Generation
A 3-10 Measurement Concept
A 3-11 Monthly Energy Input
Worksheets table of content

6. MAP of Participating companies
6

7. 7
Company Measure Saving in
kWh/a
Cost Savings in
ZAR/a
Implementatio
n Cost in ZAR
Payback period
Autopipe Switching off compressor at night 80,000 54,000 0 immediately
Fixing compressed air leakages 22,000 15,000 15,000 1 year
Switching parts washer to blower 2,000 150 0 < 1 year
Isri Repair and upgrade of heat pumps 28,000 19,000 ?? < 3 years
Reduction of temperature in degreasing
tank
2,000 1,400 0 < 1 year
Testing of powder paint with lower curing
temperatures
To be
assessed
0 < 1 year
Prism Suggested use of removal barrel insulation
blankets on five machines
75,000 51,000 50,000 < 1 year
Suggested retrofit of VSDs on three
machines
90,000 61,000 150,000 < 3 years
Repair of air leaks 24,000 16,000 0 immediate
Installation of motion detectors in sanitary
units
500 400 400 1 year
Yenza Optimizing operating time of compressor 40,000 52,000 0 immediately
Fixing compressed air leakages 20,000 26,000 2,000 < 1 year
Removing/replacing broken fluorescent
tubes
12,000 15,600 10,000 < 1 year
Sum 395,500 311,550 227,400

8. Yenza Manufacturing Port Elizabeth
– established in 1997 and employs 15 people
– spinning and pressing stainless steel components
for Tier 1+2 companies of the automotive industry
by spot and robotic welding and assembly
8

9. Yenza Manufacturing Port Elizabeth
– 60 broken but yet glowing fluorescent tubes were
replaced or switched off
-> 7,000 kWh/a
– Air leakages have been detected, new regulators,
clamps and fittings have been installed
– 55 kW screw compressor was running at very low load
of 39 %.
– compressor is now switched off completely during
nights and week ends
-> 59,600 kWh/a
9

10. Case Study 3
– …
10

11. Case Study 3
– …
11

12. Case Study 3
– …
12

13. Yenza Manufacturing Port Elizabeth
– …
13

14. Yenza Manufacturing Port Elizabeth
– …
14

15. Yenza Manufacturing Port Elizabeth
15
ECOPROFIT savings measures
Measure Annual
Resource
Saving
Annual Cost
Saving
Implementati
on Cost
Payback
period
Optimizing operating
time of compressor
40,000 kWh R 52,000 R 0 immediat
ely
Fixing compressed
air leakages
20,000 kWh R 26,000 R 2,000 < 1 year
Removing/replacing
broken fluorescent
tubes
12,000 kWh R 15,600 R 10,000 < 1 year

16. Yenza Manufacturing Port Elizabeth
“Ecoprofit has been successful project for us. It has
been a first step towards our ISO 14001
certification.“
Themba Mtati
16

17. Lessons learned
– Better together: Group setting leads to exchange
and generation of ideas and ensure lasting effect
– Keep it short and simple: Work material has to be
simple and adjustable
– No sweet without sweat: Investing time in resource
monitoring requires convincing
17

18. For further information please contact:
Dr Maik Winges
maik.winges@giz.de
082 950 6264
Thank you very much!

19. Worksheets
19
A 3-1 Energy-Inputs/CO2-Emissions
A 3-2 Significant Energy Uses (SEUs)
A 3-3 Compressed Air
A 3-4 Ventilation and Air-Conditioning
A 3-5 Refrigeration
A 3-6 IT and Workstations
A 3-7 Lighting
A 3-8 Machines, Motors and Drives
A 3-9 Heat Generation
A 3-10 Measurement Concept
A 3-11 Monthly Energy Input
Worksheets table of content

20. Worksheets
20
Company:
Use
Rated Power
[kW]
Average load
factor [%]
Hours/ Day Days/ Year Hours/ Year
Consumption
[kWh/ a]
Share of Total
Electricity uses
Compressed Air 60% 0 0 #DIV/0!
Ventilation and Air Conditioning 40% 0 0 #DIV/0!
Refrigeration 70% 0 0 #DIV/0!
IT and servers 50% 0 0 #DIV/0!
Lighting 100% 0 0 #DIV/0!
Workstations 30% 0 0 #DIV/0!
Machines 70% 0 0 #DIV/0!
Kitchen/ Canteen 80% 0 0 #DIV/0!
Heating pumps 40% 0 0 #DIV/0!
Electrical motors and drives 70% 0 0 #DIV/0!
0 0 #DIV/0!
0 0 #DIV/0!
Significant Energy Uses (SEUs) ECOPROFIT Date:
Author: Version: