ENERGY MANAGEMENT | TECHNOLOGY
presses spanning clamp tonnages from 100 to 1,200 metric tonnes. Twenty of Jabil’s sites worldwide source 100% of electricity from renewable resources as part of the company’s 2020 Climate Action Plan to reduce its operational greenhouse gas emissions. The goal is to be in line with the scientific community’s recom- mendations for limiting global warming to 1.5° C. The company aims to reduce GHG emissions
25% at its operations by fiscal year 2025, attaining a 50% emissions reduction by fiscal year 2030. Jabil uses its 2019 fiscal year emission levels as the benchmark. So far, the company has avoided the generation of 1.2m metric tons of emissions in the 2021 fiscal year through use of renewable energy. Jabil’s Mebane, North Carolina site was formerly
a production facility for Nypro, a private precision plastics moulder of healthcare, packaging, and consumer electronics products. Jabil acquired Nypro in 2013. In Jabil’s 2021 fiscal year, the Mebane facility reduced its carbon footprint from 14,000 tpa to 11,000 tpa – the equivalent of a car driving 8m miles, or powering 600 American homes. Introducing hybrid injection moulding machines to the facility accounted for 64% of the reduced emissions, with a 19% drop in GHG emissions coming from updated cooling towers and chillers. Operational efficiencies make up the remaining reduction in emissions. Jabil’s continuing focus on minimising energy use includes the introduction of real-time energy monitoring with its BMS/BAS solutions, but also the use of analytics on operational information cap- tured by their Factory of the Future solutions. Improving the injection technology with all electric or hybrid injection moulding machines and replacing old hydraulic technology when it is technically possible is another step.
Comparing machines Sustainability and energy efficiency are guiding principles for Teko-Plastic, in Preding, Austria, a producer of PP and PE injection moulded house- hold goods. The family-owned business, now in its third generation, uses recycled materials in production for circularity, and has added 6,000 m2 in solar cells atop its 18,000 m2
Above: Teko-Plastic in Austria compared energy use of a new Wittmann Battenfeld EcoPower 450 with its fleet of older Battenfeld machines
benefits of new injection moulding technology. The company compared a Battenfeld TM 4500 model with a 100 mm screw purchased in 2001 with the EcoPower model in the production of one of its staple products, a 10-litre volume bucket. Over an eight-hour measurement period, the Battenfeld 4500 consumed 68 kWh energy producing buckets on a 16s cycle time, while the EcoPower unit consumed 24 kWh of energy to produce a bucket every 13s. “Our measurements have shown that by compari- son with the Battenfeld TM, a [production] output of 115% has been possible with an energy output of only 35%,” and water consumption was lower with the EcoPower, says owner Theo Koblischek. The difference in energy requirements in favour
of the EcoPower would be even greater if both machines were equipped with screws of the same diameter, he says. The company is considering replacing all machines with up to 458 tons of clamping force with all-electric EcoPower units to realise potential energy savings of more than 60%. Energy savings of about 40% can be achieved if the larger machines are also replaced.
facility that produce
850,000 kWh of total output annually. Of that amount the company expects to use 550,000 kWh, sending 300,000 kWh to the public grid. The company operates 12 Wittmann Battenfeld injection machines at the plant ranging from 101 to 815 tons. This February it added an EcoPower 450 with an 85 mm screw to evaluate as precisely as possible the performance and energy-saving
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www.teko-plastic.com
June 2022 | INJECTION WORLD 23
IMAGE: TEKO-PLASTIC
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