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 percent 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
The BPF ’ s Energy Management in Plastics Processing guide indicates that energy usage and costs can be reduced by over 30 percent through better management , capital investment and maintenance actions .
Broanmain ’ s manufacturing capacity even further .
DRIVE UPGRADES Several years ago Broanmain invested in an all-electric IntElect featuring allelectric 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 ’ s 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 , Steven 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 , Steven 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 .
Managing Director Jo Davis concludes : “ Achieving a sustainable and viable energy reduction plan is reliant on the input and commitment of every single person . Not only does this engagement and the introduction of lower emitting technology promote best practice , it creates process improvement champions where everyone can feel confident playing their part .”
As a direct result 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 ’ s modified iPlan maintenance schedule red flags more pressing maintenance tasks to reduce machine downtime . www . broanmainplastics . co . uk
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