Energy Management in Plastics Processing: Strategies, targets, techniques and tools
About
This incredibly in-depth fourth edition Energy Management book is your one-stop-guide to strategies, targets, techniques, and tools regarding Energy Management in Plastics Processing.
Energy management is a topic that has grown in importance to every industry over the past 30 years, and the plastics industry is no exception. But many companies do not have a clear programme to reduce their energy use, costs, and carbon impact. they do not know how best to start to manage their energy use and to become more energy efficient. That's why this book covers all aspect of energy management in plastics processing - from management systems and benchmarking, through to services and operations. Each topic is covered in a single 2-page spread, providing you with a manageable explanation, clear actions, and key tips for success.
The fourth-edition of Energy Management In Plastics Processing is a sister publication to “Sustainability Management in Plastics Processing” by Dr Robin Kent - which the BPF published in 2022. This updated publication is much more specific and deals purely with energy management in plastics processing.
As with all of Dr Kent's books, this edition provides a structured approach to energy management and covers the main topics for plastics processors. It is designed as a practical workbook and does not cover all aspects of the topics but focuses on the key energy issues for each topic. Each topic is dealt with in a single two-page spread and most can be read independently of each other – this is not a ‘cover-to-cover’ book, it is designed as a resource for the industry. It should be easily understood and the actions recommended should be easily undertaken by most people
working in the plastics processing industry.
Energy management is not ‘rocket science’; it is simply good management and engineering.
All data used in this book are real industry data from plastics processing sites around the world and has only been modified to prevent identification of the sites.
Who Is This For?
This book is aimed at professionals from all parts of the plastics industry who are starting their journey in energy management. It is a practical workbook with a manageable explanation of each step, clear actions and key tips compiled from Dr Kent's 50+ years of industry experience.
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Chapters
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About the Author
 Dr Robin Kent Tangram Technologies |
Dr Kent has a B.Eng. (Hons.) in Materials Engineering from Monash University (Australia) and a Ph.D. in Polymer Physics from the University of Surrey (UK). He has been involved with polymer processing since 1971 and has worked as Technical Director for several major plastics processing companies in the UK and Europe. He established Tangram Technology in 1996 as consulting engineers for the plastics processing industry and has worked around the world in energy and sustainability management. |
Chapters
1 Introduction to energy management
1.1 Where we are going
1.2 The drivers for energy management
1.3 The importance of energy costs
1.4 The efforts, opportunities and obstacles
1.5 Energy management and net zero
1.6 Energy management – where are you now?
1.7 Financial management – where are you now?
1.8 Technical management – where are you now?
1.9 Awareness and information – where are you now?
1.10 Purchasing – where are you now?
1.11 Energy management systems – the basics
1.12 Energy management systems – the standard
1.13 Energy management systems – overview of ISO 50001
1.14 Energy management systems – where are you now?
1.15 Energy management projects
1.16 Energy management projects – where are you now?
2 Energy benchmarking
2.1 The framework and energy use drivers
2.2 The basic internal site data
2.3 The effect of management
2.4 The effect of the process
2.5 Variations on the site base and process loads
2.6 What do we want to do?
2.7 Assessing site performance – internal benchmarking
2.8 Assessing site performance – past performance
2.9 Budgeting for future site energy use
2.10 Complex sites – multi–variate analysis
2.11 Site SEC and production volume
2.12 External site benchmarking – general
2.13 External site benchmarking – injection moulding
2.14 External site benchmarking – extrusion
2.15 External site benchmarking – extrusion blow moulding
2.16 External site benchmarking – rotational moulding
2.17 External machine benchmarking – general
2.18 External machine benchmarking – injection moulding
2.19 External machine benchmarking – extrusion
2.20 External machine benchmarking – extrusion blow moulding
2.21 External machine benchmarking – injection blow moulding
2.22 External machine benchmarking – thermoforming
3 Targeting and controlling energy costs
3.1 Understanding energy use – the basics
3.2 The site energy spreadsheet/map
3.3 The site energy spreadsheet/map – process variations and estimating savings
3.4 Integrating energy into the accounts – monitoring and targeting
3.5 Data collection and analysis
3.6 Setting targets
3.7 Reporting energy costs
3.8 The energy dashboard report
3.9 Capital expenditure and equipment selection
3.10 Verifying savings – the theory
3.11 Verifying savings – the practice
3.12 The energy manager’s job
3.13 Targeting and controlling – where are you now?
4 Services
4.1 Power supply – electricity terms
4.2 Power supply – reducing electricity costs
4.3 Power supply – transformers
4.4 Power supply – voltage management
4.5 Power supply – power quality
4.6 Power supply – interval data
4.7 Power supply – interval data: shut down
4.8 Power supply – interval data: start-up and bill checking
4.9 Power supply – sub-metering
4.10 Power supply – gas
4.11 Power supply – solar and wind
4.12 Power supply – combined heat and power and tri-generation (CCHP)
4.13 Power supply – what to do when it fails (power outages)
4.14 Power supply – where are you now?
4.15 Motors – understanding motor use and costs
4.16 Motors – the programme
4.17 Motors – minimise the demand: turn the motor off
4.18 Motors – minimise the demand: reduce transmission losses
4.19 Motors – minimise the demand: reduce the driven load
4.20 Motors – optimise the supply: get the right size motor
4.21 Motors – optimise the supply: improve the motor efficiency
4.22 Motors – optimise the supply: slow the motor down
4.23 Motors – optimise the supply: the savings from slowing motors down
4.24 Motors – motor management and maintenance
4.25 Motors – where are you now?
4.26 Compressed air – the system
4.27 Compressed air – the programme
4.28 Compressed air – minimise the demand: reduce leakage
4.29 Compressed air – minimise the demand: reduce use
4.30 Compressed air – optimise the supply: reduce generation costs
4.31 Compressed air – optimise the supply: reduce treatment costs
4.32 Compressed air – optimise the supply: improve distribution
4.33 Compressed air – heat recovery
4.34 Compressed air – where are you now?
4.35 Cooling water – the programme
4.36 Cooling water – minimise the demand: reduce parasitic heat gains
4.37 Cooling water – minimise the demand: increase temperatures
4.38 Cooling water – optimise the supply: reduce cooling costs with chillers
4.39 Cooling water – optimise the supply: reduce cooling costs with cooling towers
4.40 Cooling water – optimise the supply: reduce cooling costs with free cooling
4.41 Cooling water – optimise the supply: reduce cooling costs with ground water
4.42 Cooling water – optimise the supply: reduce distribution costs
4.43 Cooling water – where are you now?
4.44 Drying – the programme
4.45 Drying – minimise the demand: dry the right materials
4.46 Drying – minimise the demand: store materials correctly
4.47 Drying – optimise the supply: improve control systems and insulation
4.48 Drying – optimise the supply: reduce drying costs with desiccant drying
4.49 Drying – optimise the supply: reduce drying costs with other methods
4.50 Drying – where are you now?
4.51 Vacuum generation
4.52 Raw materials handling
4.53 Robots
4.54 Hydraulics systems
4.55 Fans
5 Processing
5.1 Processing – where are we going?
5.2 Processing – machine production rate
5.3 Processing – materials
5.4 Injection moulding – where does all the energy go?
5.5 Injection moulding – the basics
5.6 Injection moulding – machine selection
5.7 Injection moulding – machine monitoring
5.8 Injection moulding – process setting
5.9 Injection moulding – motors
5.10 Injection moulding – new and retrofitted VSDs
5.11 Injection moulding – servomotors
5.12 Injection moulding – all-electric machines
5.13 Injection moulding – barrel heating
5.14 Injection moulding – mould temperature controllers
5.15 Injection moulding – mould design and maintenance
5.16 Injection moulding – hydraulic fluid
5.17 Injection moulding – energy rating
5.18 Injection moulding – where are you now?
5.19 Extrusion – general
5.20 Extrusion – motors
5.21 Extrusion – heating
5.22 Extrusion – profiles
5.23 Extrusion – profiles: calibration and cooling
5.24 Extrusion – sheet
5.25 Extrusion – blown film
5.26 Extrusion – oriented film
5.27 Extrusion – other processes
5.28 Extrusion – where are you now?
5.29 Extrusion blow moulding – general
5.30 Extrusion blow moulding – motors
5.31 Extrusion blow moulding – extrusion and blowing
5.32 Extrusion blow moulding – heating and cooling
5.33 Extrusion blow moulding – tops and tails management
5.34 Extrusion blow moulding – where are you now?
5.35 Injection blow moulding
5.36 Injection blow moulding – where are you now?
5.37 Injection stretch blow moulding – general and moulding
5.38 Injection stretch blow moulding – blowing
5.39 Injection stretch blow moulding – where are you now?
5.40 Thermoforming – general
6 Operations
6.1 Operations – making it work
6.2 Setting, start-up, stand-by and shut-down
6.3 Shut–down measurement and control
6.4 Tool changeover and quality control
6.5 Training and employee involvement
6.6 The benefits of employee training
6.7 Processing operations – where are you now?
6.8 Maintenance strategies
6.9 Maintenance for energy management
6.10 Small power equipment
6.11 Small power equipment – where are you now?
6.12 Process control
6.13 Process control – where are you now?
7 Buildings and offices
7.1 Buildings and offices
7.2 Lighting – general
7.3 Lighting – controls and maintenance
7.4 Lighting – where are you now?
7.5 Heating – general
7.6 Heating – controls and maintenance
7.7 Heating – where are you now?
7.8 Hot water – where are you now?
7.9 Air conditioning
7.10 Air conditioning – where are you now?
7.11 Building fabric
7.12 Building fabric – where are you now?
8 Site surveys
8.1 The mini site survey – the energy walk-around (the treasure hunt)
8.2 Preparing for the site survey – information
8.3 Preparing for the site survey – tools
8.4 Planning the initial site survey
8.5 Carrying out the initial site survey
8.6 Reporting the initial site survey
8.7 Following up the initial site survey
9 Carbon footprinting
9.1 The basics of carbon footprinting
9.2 Site carbon footprinting – Scope 1
9.3 Site carbon footprinting – Scope 2
9.4 Site carbon footprinting – Scope 3
9.5 Site carbon footprinting – Putting the scopes together
9.6 Carbon neutrality
9.7 Carbon neutrality – offsetting
9.8 Supply chain emissions
9.9 Product carbon footprinting
9.10 Country plastics processing carbon footprints
9.11 Carbon footprinting – where are you now?
