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.