How we managed to to work with a site that rarely shuts down production & still increase production yield
GLASS MANUFACTURER
nsw
CLIENT: confidential
PROJECT TYPE: ENERGY PERFORMANCE CONTRACT
Industry: INDUSTRIAL
Status COMPLETED
the challenge
The Glass manufacturing site at Penrith runs 24 hours a day, 7 days a week. The glass furnaces providing molten glass do not shut down unless undergoing major refurbishment every ~10 years. The machine line shut downs are usually for changes of glass colour, allowing the team only a few hours to install and commission equipment once every 2-3 months. The timing of colour changes could change unexpectedly down to a few days before each outage, presenting considerable coordination challenges for our Project Management team.
The solution
Climatech Zero worked closely with the site team, ensuring that our installation and commissioning works were planned and ready to fit with colour changes. The team had to remain flexible and ready to jump as soon as the timing was locked in.
The results
Over the course of 4 separate outages, attending site from 3am to midday for one system, 11pm until 7am for another, the CZ team integrated, tested and commissioned 4 new fan control PLCs, as well as a brand new machine cooling fan for one line. Each time, good planning and communication led to successful implementation and immediately measurable results.
- Project payback 0.7 years
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Annual increased production yield $400,000
Annual energy cost savings $233,000 - Annual reduction 1,600 tCO2