Auckland Council Large Energy User Award
The Auckland Council Large Energy User Award recognises a business that has completed a successful energy efficiency or renewable energy initiative as part of a wider energy management strategy.
- Winner – Orora Beverage Cans New Zealand
- Highly Commended – ANZCO Foods
- Commended – Nelson Pine Industries Ltd
Stand-out energy efficiency achieves record results for production.
Profits are up and greenhouse gas emissions are down at Orora Beverage Cans’ plant in Wiri, in south-west Auckland. Drinks cans are flying off the production line with world-class efficiency as 30% savings in electricity, gas and greenhouse gas emissions are realised.
Previously the worst performing of Orora’s sites, Wiri has been transformed into a model of business growth and sustainability through energy efficiency. Orora conducted a group-wide energy audit which found Wiri in need of major improvements in technology and processes to remain competitive and reduce wasted energy.
Air-leakage surveys were performed and adjustments made where necessary. When mechanical repairs could not meet energy efficient standards, high-performing new technology was installed to replace the old, including heating and lighting controls. Energy efficient variable speed drive technology has been installed for air-compressors, pumps and vacuum fans and, finally, insulation on heating water reticulation and washer tanks puts a stop to wasted energy in the form of heat loss.
Since energy-management work started in 2013, Orora has seen energy use drop by around 30% and productivity increase by 30%. The recent installation of LED lights and optimisation of compressed air systems installed in 2015 now has the Wiri site on track to produce a million cans using only around 15,500 kilowatt-hours of energy, which is world-class efficiency.
Other Orora sites are set to benefit from the experience at Wiri, which is raising the bar in energy efficiency. Companies with similar industrial setups can also look to Orora’s example for improving their productivity through energy efficiency.
There was a lot to gain in energy and cost savings and everyone worked together to achieve them.
ANZCO had its sights set on some big energy savings from the start, but it was a surprise to everyone how quickly they would be achieved. The success is down to a company-wide commitment to be more energy efficient and the results speak for themselves: two years ahead of schedule they’re saving 36 gigawatt-hours of energy a year.
As a well-known face of New Zealand industry, ANZCO had much to gain from setting high standards in sustainability. The company is a key player in achieving New Zealand’s carbon reduction targets and its efforts to date have made it the energy efficient poster-child within its sector.
A partnership between ANZCO and energy management experts, DETA Consulting, brought about the early results. DETA helped set up energy-management committees at each of ANZCO’s nine sites, a move that set in motion group-wide support for sustainability.
ANZCO understood that to achieve the level of returns they were looking for in fuel and cost savings, an investment from the company would be required. A capital works programme to the tune of $3.9 million was implemented to upgrade hot water systems, improve refrigeration and replace old plant with state-of-the-art, energy efficient technology. The investment is being quickly recouped in reduced fuel bills: so far, ANZCO has achieved a 16.9% reduction in overall energy use, saving $2.6 million each year.
Energy efficiency targets are now being re-evaluated at ANZCO and a new target is due to be set for 2017 based on their current swift rate of progress.
Energy use has reduced by 20% and more than 11,000 tonnes of greenhouse gas emissions have been saved.
Nelson Pine’s energy-saving journey started back in 2008, but recent adjustments to their long-term energy management plan have trebled their anticipated energy-related cost savings to over $3 million per year.
A large amount of Nelson Pine’s energy use goes towards moving air around the plant for the purpose of fume extraction and fibre transfer, so when they installed energy efficient fans it had a substantial impact on cumulative energy use. Likewise, energy efficient refining discs used to cut materials have reduced energy use and this is topped up by their switch to low-energy LED light fittings.
Since the additions to Nelson Pine’s energy management plan were made in 2010, they have saved a total of 11,200 tonnes of greenhouse gas emissions. At the same time, productivity levels have increased by 10.6%. These achievements are celebrated in the ‘Green Report’, which is a feature of the Nelson Pine Newsletter that keeps staff in touch with progress and recognises their collective contribution.
As a whole, the site has reduced its energy use by 19%, which has considerably lessened the strain on the electricity network in the area. Nelson Pine Industries is in the process of developing an energy-specific company policy as part of embedding energy management in its strategic direction and as all new projects are assessed for energy efficiency, the savings are set to continue.
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Since amalgamation, Auckland Council has been on a steady and evolving climate leadership journey, and serving the nearly 1.5million residents of Auckland. Auckland Council leverages scale and influence, taking active leadership, employing and defining best practice and bringing together others to create community-wide change.