powEr, EnErgy & rEnEwablES These challenges demonstrate the


importance of a robust plan that anticipates disruption to future output. In light of this, temporary procurement strategies offer an innovative approach for industry to navigate the transition to sustainable energy while protecting all-important bottom lines. Hired energy and temperature


control solutions can help existing facility infrastructure adapt to external circumstances, offering an alternative solution for manufacturers. Temporary power can be scaled up or down - an important advantage in today’s uncertain trading conditions where demand fluctuates, and a stable grid cannot be guaranteed. Through these equipment measures, significant efficiency improvements can be achieved without having to impact capex budgets - an important advantage as financial margins become increasingly fine for manufacturers. Ultimately, the drive to improve the


sector’s sustainability falls on suppliers that, by improving their own fleets and processes, can work to make positive industry changes that lower emissions and maintain the bottom line. By possessing necessary expertise and up-to-date technologies, suppliers can support businesses’ ability to manoeuvre within the current energy crisis and adapt their production measures in the face of continual industry change. Aggreko’s Greener Manufacturing


Upgrades, for example, offers industry the best chance of cutting emissions and fuel consumption without sacrificing output. For instance, by investing in more sustainable products and offering customers cleaner technologies and alternative fuels such as Hydrotreated Vegetable Oil (HVO) we are supporting industry towards a low-carbon future.


PuTTiNG iNDuSTRy oN THE FRoNT FooT A temporary procurement approach places manufacturers on a firm footing to take on immediate industry challenges while addressing long-term industry trends and uncertain market forces. Increasing energy efficiency should not hit manufacturer bottom lines. In fact, the opposite is true, and innovative approaches to procurement are essential to this. Ultimately, the inability to predict does not equal the inability to prepare when it comes to equipment procurement.


Aggreko www.aggreko.com


UKManufacturing Winter 2022


parts. Despite the welcome six month reprisal, as we hurtle into winter, even capping the costs at less than half the market rate is still a cost pressure that is hard for the most energy efficient business to absorb. The BPF’s Energy Management in Plastics


powEring through: T


Moulding SME prEpS for EnErgy Manufacturing criSiS


his energy crisis is a worry for every individual and enterprise. Not least manufacturing SMEs that are utterly reliant on power to make


Processing guide indicates that energy usage and costs can be reduced by over 30 per cent through better management, capital investment and maintenance actions. Although there is not a single ‘megawatt’ energy saving solution - moulding technical components requires power after all - Broanmain’s new maintenance engineer Steven Romano has taken the lead (and a leaf out of the BPF book) and introduced a number of process and site improvements to help cushion the financial shock.


SiTE iMPRovEMENTS A planned maintenance regime might not sound like a Eureka! energy saving scheme, yet as part of a continual improvement programme can deliver surprising and quick results. As testament, Romano has spent the past six months examining Broanmain’s entire fleet of machinery and created a modified iPlan maintenance schedule that red flags more pressing maintenance tasks to reduce machine downtime. Aligned to the company’s material waste reduction


and First Time True quality culture, he explains: “Having this schedule keeps our technologies running as cleanly and efficiently as possible, cutting our production carbon footprint even further.” Having worked in maintenance for more than 30


years, from his experience Romano estimates that an effective maintenance regime can reduce unplanned machine breakdowns by as much as 60 per cent. Another simple routine to introduce is


monthly air and water filter changes, states Romano. Cleaner water protects tools. Less rust also reduces system contaminations, preventing component defects and material waste. Plus significantly improves heater efficiency.


LivE DASHBoARD DATA Tapping into energy supply data over the Wi-Fi, the team can now view exactly what it is costing by the hour to run the company’s fleet of 11 injection moulding machines, plus all ancillary, finishing and tool making equipment. Even slight modifications, e.g. barrel insulation to contain heat, has already resulted in visible energy saving improvements.


Fix CoMPRESSED AiR LEAkS Experts estimate between 20 and 40 per cent of generated compressed air is lost due to leaks. Broanmain has addressed this by putting in two isolation valves and shutting them off for the building and compressor, as well as incorporating a routine inspection and reporting system for air leaks. These actions, along with a new timer controller on the compressor, is saving the company in the region of £17,000 yearly.


DouBLE SHiFTS SLASHES PoWER-uP CoSTS Given that the most energy intensive process in injection moulding is heating material up, to limit machine start-ups, Broanmain has moved virtually all production to one site and now operates two overlapping day and night shifts Monday to Thursday. Combined with carefully-considered production


sequences, fewer machine shut offs, tool changeovers and restarts, is proving to be more productive and cost efficient, and increases Broanmain’s manufacturing capacity even further.


DRivE uPGRADES Several years ago Broanmain invested in an all-electric intElect featuring all-electric drive technology from Sumitomo (SHi) Demag. However, the remainder of its injection moulding machinery park is a blend of hydraulic and hybrid technology. in order to optimise investments while


simultaneously improving efficiency, the firm is currently exploring the benefit of upgrading to variable speed drives to save energy use during the curing time. To benchmark the savings, this will initially be rolled out on the company’s largest hybrid machine.


PoWER To iTS PEoPLE An energy efficient and robust production plan and maintenance programme is only as good as the data sourced, measured and benchmarked. However, it is the small actions taken by the entire workforce through better engagement and communication that can make the biggest dent in energy bills. Commenting that energy consumption is not


purely about machinery assets, but equally the actions taken by staff, Romano expands: “it’s a refreshing change to see workforce suggestions roll out so swiftly. it feels like everyone across the firm is thinking like a process optimisation and energy custodian.” Since joining the moulding firm in May 2022,


Romano has shared with the entire workforce and management a toolbox of tricks and tips to curtail energy consumption. This includes seeking feedback on future actions. one staff suggestion put forward and currently being instigated includes designing a machine shut-off traffic light system. Providing clear unsupervised visual instructions and flagging when guidance should be sought by production managers. As a direct result of all of these energy savings,


Broanmain has been able to pull forward pay increases to support its workforce with the cost of living crisis, as well as introduce new flexible working arrangements, including an early Friday finish, to nurture a better work/life balance.


Broanmain Plastics www.broanmainplastics.co.uk


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