INCREASINGLY, concerted efforts are being made by manufacturers to reduce the environmental footprint of their operations, and some have made significant advances in aiming for a carbon neutral outcome.
Tuftmaster Carpets, one of Australia’s largest carpet manufacturers, has taken a holistic view in its approach to energy, water and materials usage, and plans to be carbon neutral in its operations by 2015, which is a strategy that anticipates the future introduction of a national carbon trading scheme.
According to environmental manager, Demi Taylor-Blake, the company’s Environmental Management System (EMS) has been integrated into ISO 9001/2000 and this has led to recent ISO 14001 and 14024 Type 1 Environmental Labelling accreditation.
“An internationally recognised EMS can provide valuable marketing and trade advantages for a company. Many countries are likely to favour ISO 14001certified companies in procurement contracts, and Australian Government departments are also heading down this track,” she told Manufacturers’ Monthly.
“We are following a path of continual environmental improvement which includes compliance with environmental legislation and prevention of environmental pollution.
“Currently, 25% of our electricity is procured from accredited GreenPower to offset carbon emissions and, through incremental purchasing of GreenPower and energy savings measures, the company aims to become carbon neutral.
“An energy management system has been implemented and energy savings initiatives include a continuing upgrade of our entire manufacturing facilities to reduce overall energy consumption.
“For example, a feasibility study is underway into boiler efficiency and heat recovery options whereby waste heat generated by the boilers and carpet backing line is utilised to heat the factory buildings. Analysis of boiler gas consumption is now carried out as part of the regular maintenance program.
“A new spinning system is also being installed to save energy with a payback period of only one year for a capital outlay of nearly $1.8m. Other initiatives include the installation of flow reduction nozzles on compressed air clean-up hoses and isolation of pneumatic controls on machines that are not in use.
“In relation to lighting, energy efficient lighting has been adopted, motion activated lighting controls are being considered in offices, and outside lights are connected to a photoelectric cell and time switch. An energy audit is carried out every quarter.”
In addition to the range of energy saving actions, Tuftmaster has ensured that all its carpet is recyclable.
Cogeneration benefits
In a joint project with AGL, and with support from the Victorian Government, a major on-site green energy generation facility has been commissioned at Symex Holdings’ soap manufacturing plant in Port Melbourne.
At a capital cost of some $4.2m, the 4.4MW cogeneration unit is operating under a 15-year build-own-operate arrangement whereby AGL supplies electricity from the gas-fired generator to Symex, and excess power is exported to the grid for on-selling to Symex’s subsidiary Pental Soap Products in Shepparton.
Symex production manager, Peter Costello, says heat from the turbine is recovered and converted into low pressure steam in the existing heat recovery steam generator.
“The cogeneration plant replaces most of the natural gas, formerly used for low pressure steam generation, with exhaust heat from the gas turbine.
“All the existing infrastructure is reused in the project including the high and low voltage electrical system, gas reticulation, steam, and feed water reticulation,” Costello said.
“Our Port Melbourne site is now capable of operating independently from the grid. Some 13,500MWh is being used by the total site, and the excess 15,100MWh is provided to the grid,” he said.
Manager project implementation at AGL, Cyril Arambage, says increasing regulations aimed at countering the greenhouse effect are resulting in a greater focus on ways to increase the efficiency of energy generation.
“Also, the price of electricity is escalating, which in turn means that alternative technology is becoming more feasible and viable,” he said.