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ENERGY EFFICIENCY AND
ENERGY MANAGEMENT IN
INDUSTRIAL COMPANIES
Editorial




ENERGY EFFICIENCY AND ENERGY MANAGE-
MENT IN INDUSTRIAL COMPANIES
Many industrial companies are increasingly focusing on energy efficiency as a
way to be sustainable.
This Insight Report addresses this issue and explores a subject which is still
new ground for many companies.

When it comes to energy efficiency, much de-
pends on a company’s ability to identify new
                                                               From disposal to utilisa-
approaches. Saving energy is not that difficult if             tion
plenty of energy is being wasted. This explains
the scepticism among some experts about com-                   Just like the waste disposal industry, many
panies purchasing "green" energy. Most indus-                  companies will also have to reinvent themselves
try representatives consider this to be the                    with a view to energy efficiency. Although the
wrong approach. They claim that it is much                     physical items to be disposed of have not
more important to stop wasting energy in order                 changed, they are now referred to as ‘secondary
to boost one's own energy efficiency.                          raw materials’ in a recycling industry. The dra-
                                                               matic change in this industry is a good example
                                                               of how the use of resources is developing in
                                                               Germany and the EU. The main objective is to
                                                               generate maximum value from the use of a
                                                               particular resource, be it a secondary raw mate-
                                                               rial or energy. Just as with physical waste re-
                                                               processing, the key question now is how energy
                                                               can be retained or re-used.

                                                               This question does not just extend to manufac-
                                                               turing plants, but also to utility companies,
                                                               where the first signs of significant energy saving
                                                               are being seen. Most power stations in Germany
                                                               and elsewhere operate cooling towers or cooling
                                                               basins. What people perceive as rising steam is
                                                               nothing but an enormous cloud of heat energy
                                                               that is simply blown out into the atmosphere.
                                                               Those who understand and accept this fact may
                                                               come up with the idea of converting their own
                                                               factory into a cooling tower in order to access
                                                               this vast quantity of energy. Paper mills, for
                                                               instance, are already adopting this method to
                                                               feed their energy-intensive processes. Although
                                                               this is a good energy supply concept, it is just
                                                               the beginning of the possible value cycle.

                                                               Another example from the waste disposal sector
It is not particularly difficult for many companies            might serve to explain this approach in more
to increase their energy efficiency. This begins               detail. Let us look at the paper industry, which
when companies realise that their plants dis-                  today is intrinsically linked to waste disposal and
charge energy, for example as heat, into the                   recycling. Since the introduction of recycled
environment. This is an issue that has been                    paper, the value chain of this resource has wit-
somewhat neglected up to now. We often treat                   nessed dramatic progress. Whilst the only dis-
energy in much the same way as we did domes-                   tinction made in the early days was between
tic and industrial waste just a few years ago,                 paper and recycled paper, companies today
considering it as nothing but a byproduct to be                distinguish between around 15 types of recycled
disposed of. For business as well as environ-                  paper. Each of these varieties represents a spe-
mental reasons change is necessary and will                    cific grade of this raw material. The original
happen.                                                        resource - wood fibre – now has a spiral-shaped


                                                             2
     T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
product life cycle. In this cycle, the                                               had major repercussions on com-
spiral turns 15 times before the                                                       panies' efforts to boost efficien-
original wood fibre can no long-                                                        cy. Now that energy prices are
er be used. The end of the
                                                                                      picking up again, the energy
spiral is marked by ‘thermal
utilisation’ – burning - when                                                        efficiency issue is once again
energy is recovered from                                                              entering centre stage for busi-
the residual fibre. Com-                                                               ness leaders.
pared to this, the use of a
power plant’s residual energy                                                     One can generally identify sev-
in the example mentioned                                                         eral elements that can be used to
above represents just two cy-                                                     boost corporate energy efficien-
cles in a value spiral – the ener-
                                                                                  cy. Besides almost trivial things,
gy being used once at the power
station and ‘recycled’ once when the paper mill                                   such as managing the lighting
uses its residual steam as an energy source.                      or           heating of business premises, ener-
However, here are potentially a much larger                       gy efficiency extends to the production process
number of re-uses conceivable.                                    as well as the use of residual energy (energy
                                                                  recovery). Companies active in this field have
Economic efficiency and                                           already adopted a very proactive view of these
sustainability                                                    elements. Companies will now also find it
                                                                  worthwhile to consider the engineering of their
Some companies have taken to heart not only                       own plants, their production processes and even
the economic benefits of energy efficiency, but                   their own products’ construction in light of the
also the role of sustainability. Environmental                    energy efficiency issue.
responsibility and business reputation have an
important role to play in this area. This is why                  Many energy efficiency measures do not even
companies are at times exploring projects where                   require a budget to be implemented and pay off
the return on investment takes five years or                      from the very first day. The only questions to be
more to materialise. However, energy cost re-                     answered are: "To what extent are companies
ductions remain the driving factor. Not surpris-                  willing to give priority to energy efficiency?",
ingly, there has been a strong correlation be-                    and "What approaches will they adopt?"
tween energy efficiency and the global econom-
ic crisis in recent years. Slumping energy prices




CONTENTS
Energy efficiency and energy management in industrial companies ............................................. 2
Seven steps to improving energy management at companies ...................................................... 4
Energy efficiency regulation tightens ......................................................................................... 5
16001 – and what comes next? ................................................................................................ 6
Internal and external influences in coming years - act vs react .................................................... 7
Energy efficiency analysis in practice ......................................................................................... 9




                                                               3
       T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
Parameters of energy efficiency



Seven steps to improving energy management at
companies
The discussion about the optimum energy use and the projects that have been
implemented so far are so different that they show several approaches are
available when it comes to boosting energy efficiency. The following discussion
provides an overview of the individual steps to energy efficiency and optimisa-
tion.

Energy efficiency often starts with a company's                of measures. The steps                  towards      energy
executive management. Work on energy                           efficiency are as follows:
efficiency, however, often starts at middle
management. Companies usually appoint an                       I. Identify waste: Where is power used un-
energy efficiency officer who often lacks                      necessarily?
detailed knowledge of the subject. The typical
                                                               II. Avoid a throw-away mentality: How can
                                                               residual energy be put to good use?

                                                               III. Load management: How can the compa-
                                                               ny or its production processes realistically be
                                                               organised to reduce peaks in energy demand?

                                                               IV. Production efficiency: How can plants
                                                               and production lines be operated in the most
                                                               energy efficient manner?

                                                               V. Machinery efficiency: Which machinery is
                                                               the most energy efficient available?

                                                               VI. Process efficiency: Which production
                                                               method minimises energy consumption in mak-
                                                               ing the product?

                                                               VII. Product efficiency: How can I design my
                                                               product in an energy-efficient manner?



                                                               Each of these steps can be considered and ap-
                                                               plied individually. However, in practice most
                                                               companies initially consider energy recovery and
approach is to take a simple look at energy
                                                               preventing energy waste before other steps are
efficiency measures available to a company. On
                                                               taken.
the basis of the measures already implemented
by active companies, seven steps can be
identified which serve as the basis for a range




                                                             4
     T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
Legal framework



Energy efficiency regulation tightens
Besides rising energy prices, legal requirements and regulatory mechanisms
can also drive energy efficiency measures. There are several plans to regulate
energy use on a German and EU level.

„Political, social and environmental influences                 the conditions for payment of the incentive in
force you to address the issue of energy man-                   the US was the purchase of a low-consumption
agement." Dr. Jörg Meyer (Head of the Energy                    car model. This also offered an enormous
& Climate Protection Unit, Siemens AG)                          competitive advantage for companies which had
                                                                embarked on efficient models at an early stage.
 This statement suggests that, in addition to                   This shows that energy management can be
social influences and environmental aspects,                    considered as a competitive advantage.
political conditions will also become increasingly
demanding. Apart from DIN EN 16001 and ISO                      "Energy management saves time so that
50001 standards (the subject matter of a                        companies are able to act rather than merely
separate article in this Insight Report), the first             react," notes Dr. Jörg Meyer.
far-reaching interventions have already been
made in one of industry’s sovereign areas:                      It seldom makes sense to lag behind official




                          Dr. Jörg Meyer, Head of the Energy & Climate Protection Unit, Siemens AG




product design. A widely known example is the                   rules. The current reluctance to implement                 the
gradual implementation of the ban on energy-                    EU's energy goals suggests that regulations                will
inefficient light bulbs. With this regulatory                   become even more restrictive. Therefore                     an
intervention the issue of product efficiency, long              active   energy    strategy    can   only                   be
neglected by many companies, is increasingly                    advantageous.
significant.

Pressure on other industries is also growing.
The automotive industry has already committed
itself to greater transparency in its energy
consumption. Pressure from the consumer end
has also increased significantly in recent years.
This step seems to be long overdue considering
that an energy consumption limit has been in
use for several years in the electronics industry.
In the automotive industry’s case it was in fact
the US which pioneered regulation, where the
"cash for clunkers programme" proved to be a
trailblazing concept. Unlike in Germany, one of


                                                             5
     T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
Legal framework



16001 – and what comes next?
No - this is not an outlook to the year 16001. Instead, it refers to the imple-
mentation of the DIN EN 16001 standard for energy-intensive companies. It
should not be long before this standard is implemented because it is currently
triggering many questions for businesses. One particularly important question
concerns the features of an energy management system that is certified ac-
cording to DIN EN 16001.

"16001 merely sets the                                                               system certified. It can be
basic parameters. It is left                                                         achieved either through a
to the companies them-                                                               functioning       environmental
selves to decide how to                                                              management system that is
implement these parame-                                                              certified according to ISO
ters. A car maker will ap-                                                           14001 or through an eco-
proach this issue differently                                                        management         and     audit
from, say, a fan manufac-                                                            scheme (EMAS). The third
turer."   Sylvia     Wahren                                                          option is the provision of proof
(Fraunhofer Institute for                                                            in another suitable form. This
Manufacturing Engineering                                                            is contingent upon appropriate
and Automation, TEEM)                                                                data capture as well as evalua-
                                                                                     tion of the savings potential
This statement summarises                                                            according to ecological and
the underlying idea of this                                                          economic criteria. Since 1 July
standard. 2009 marked the                                                            2009, the DIN EN 16001
beginning     for    energy-                                                         standard has been offering
intensive companies. Since                                                           companies the ability to certify
then, they have been able                                                            their own environmental man-
to benefit from a compen-                                                            agement systems. The stand-
sation rule via the Renewa-                                                          ard sets out the framework for
ble Energies Act. The legis-                                                         such a system. Furthermore,
lator has made this benefit                                                          DIN EN 16001 is also a good
contingent upon the intro-                                                           basis for companies when it
duction of an EnMS (energy Sylvia Wahren, Fraunhofer Institute for Manu-             comes to obtaining future
management          system). facturing Engineering and Automation, TEEM              certification according to the
Companies consider this                                                              international requirements of
aspect to be the most diffi-                                                         ISO 50001.
cult issue because such a
system must be certified.                                                Although    regulators  have
Readers interested in more                                               granted relatively ample lee-
detailed information in this respect are well way, there is still a high degree of uncertainty
advised to take a first look at the guide for among companies who do not yet know what
companies and organisations published by the features an energy management system must
German Federal Environmental Agency (DIN EN have in order to qualify for additional DIN EN
16001: "Energiemanagementsysteme in der 16001 certification as an environmental man-
Praxis"; source: www.umweltbundesamt.de). agement system. In addition, there are only a
Many questions are answered there.                     few systems available that can be implemented
                                                       "out of the box" and already include certifica-
The Renewable Energies Act offers three differ- tion.
ent ways of having an energy management




                                                             6
     T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
Influence parameter



Internal and external influences in coming years
- act vs react
Corporate energy efficiency and energy management are subject to a host of
influences. Besides energy costs as the most important influence, further ex-
ternal and internal forces influence the development of this issue.

Experts agree on one point: There will be strong               impact on the development of corporate energy
demand for energy efficiency measures in the                   efficiency. Other influences include an increas-
years to come.                                                 ing scarcity of raw materials, new production
                                                               methods, more efficient processes and the cost
Many companies already regard energy                           of replacements.
management as a competitive advantage. This
not only applies to competition between the                    All companies are equally exposed to these
individual players on the market; energy                       factors, no matter whether or not a company
                                                                   has an energy management system. The
                                                                                   question is not so much
                                                                                   whether a company will
                                                                                 address the energy issue but
                                                                             when this will happen. A
                                                                             company’s strategy might be
                                                                             active         or     reactive     to
                                                                             circumstance; either strategy can
                                                                            be right or wrong. Simply put, an
                                                                             active strategy is, for instance,
                                                                                chiefly suitable for energy-
                                                                                  intensive companies and not
                                                                                   for companies where energy
                                                                                       is a relatively minor cost
                                                                                         item. The latter can
                                                                                        afford to merely respond
                                                                                     to regulatory intervention
                                                                                      and hence to limit their
                                                                                             action to what is
                                                                                                        absolutely
                                                                                               necessary in this
                                                                                             respect.

                                                                                              The pressure to-
                                                                                              wards    efficiency
                                                                                              puts an additional
                                                                                              burden on small
                                                                                            energy    consumers
                                                                                         whilst energy-intensive
efficiency                       also has a                    companies can use it as a new way to play an
role to play when it comes to competition                      active role in the market. The pioneers will inev-
between geographic areas. Energy efficiency                    itably force the field to follow suit.
can also prevent sites from losing their
competitiveness to competitors in low-wage
countries. The competition factor consequently
influences a company's energy management
strategy      not    just  through    internal,
entrepreneurial interests, but also through
external influences.

It goes without saying that the legal conditions
mentioned earlier also constitute an important
external factor. Just like energy prices and com-
petition, the legal framework also has a positive


                                                             7
     T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
On Demand



Technical papers available on demand
More detailed technical papers on corporate energy efficiency and energy management
are now available on demand.




     Selected technical papers presented by leading companies at our technical conference on "In-
     dustrial Energy Efficiency and Energy Management", 27 to 28 October 2010, were rec-
     orded live.

     Did your schedule prevent you from attending our event, or do you want to revisit selected
     talks? With our "On-demand special", we give you the opportunity.

     Make use of this opportunity, and you will also receive the digital conference material (on CD) in
     addition to your personal access to the recorded talks.

     Under the following link www.UnityLivestream.com/TACookDemo you can examine the record-
     ing quality and view short clips from some papers.




                                                                 8
         T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
Energy efficiency analysis



Energy efficiency analysis in practice
Before implementing an energy management system, a company should first
perform an efficiency analysis. WKW Automotive and Amcor Flexibles Singen
are good examples of successful implementation projects.

 WKW Automotive (aluminium processing) and                     Furthermore, an efficiency analysis can also
Amcor Flexibles Singen (manufacturer of                        help to identify incorrect energy bills.
primary packaging) are demonstrating how an
efficiency analysis can be successfully carried
out.     In   WKW's     case,  a     successful
implementation enabled a return on investment
for the entire project in
eight months. Careful
performance      of    an
analysis can be the
foundation for a quick
return on investment.

Different approaches can
be taken for an analysis.
Many     companies,      for
instance, rely on their
own,      company-specific
solutions.            Other
companies,      such      as
Amcor Flexibles Singen,
rely      on      standard
methods, such as Six
                                                               Ulrich Leutgeb, WKW Automotive
Sigma in order to analyse
their energy demand. A
sound database is vital in
either case. Companies
first need to identify their
energy consumption from different sources and                  How can an analysis cause
integrate these into an energy data
management system. Every significant energy
                                                               changes in load distribu-
load should be fitted with a dedicated metering                tion?
unit; measurements at fifteen minute intervals
tend to work well for tracking load curves. Many               WKW learnt from its efficiency analysis that the
companies need to invest in an IT infrastructure               energy consumption of a plant or line is
composed of meters and data capture points.                    dependent not just upon the load (i.e., the plant
This may well mean a five-digit investment. But                or line), but also upon the product that is
such an investment can pay off even if no                      currently being manufactured. WKW Automotive
energy is saved at all.                                        quotes two practical examples:

In the case of WKW, for instance, an analysis
enabled a better distribution of the company's
                                                               Curing ovens
energy load curve so that peak load demand
could be reduced. If a company manages to                      "Certain products need more energy than others
reduce its peak load by one MW through                         in the oven. Once we understood this,
changing its load distribution pattern, this                   production of energy-intensive products can be
generates savings of around €7,000 per month                   shifted to the night shift when energy is cheaper
without a reduction in energy consumption. This                and the load curve low. However, the human
peak load reduction also generates a certain                   factor is important here. It would be no use if all
measure of sustainability. The price of energy in              the ovens entered the heating-up phase
Germany could be significantly reduced if                      simultaneously. Needless to say, they have to
companies managed to handle their peak loads                   start in succession” Ulrich Leutgeb (WKW
better, as utilities’ activities to balance peak               Automotive)
loads are a particularly significant cost factor.


                                                             9
     T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
Extrusion presses                                                   delivering to customers is what matters.
                                                                    The onus does not have to be left entirely
"Certain alloys require more power in
the press. These alloys were
previously often produced during the
day. Without an energy management
system, this consumption would not
have been visible” Ulrich Leutgeb
(WKW Automotive)

These two examples show to what
extent an efficiency analysis can
affect operational structures and the
possibilities which this opens up for
companies. With such an analysis,
WKW Automotive managed to
optimise its own production without
changing the product or delivery
times. At Amcor Flexibles Singen, an
analysis formed the basis for                                         Peter Ritter, Amcor Flexibles Singen
redesigning and optimising the
factory's entire lighting system.


                                                                    to production. As soon as consumption is
The benefits at a glance                                            transparent, they will develop their own
                                                                    ideas and identify their savings potential."
Apart from the above-mentioned benefits of an                       Ulrich Leutgeb (WKW Automotive)
analysis, further advantages include:                              "You do not always need direct KPIs for Six
                                                                    Sigma. You may also use somewhat less
 The     introduction     of   the   energy                        exact KPIs as long as there is enough
  management system leads to a clearly                              potential because you can achieve a lot in
  reduced load curve. The peak load can be                          this way.” Peter Ritter (Amcor Flexibles
  reduced by more than 10%.                                         Singen)
 The measures described enable a significant                      “Quick wins are possible even without Six
  reduction in the price per kWh.                                   Sigma.” Peter Ritter (Amcor Flexibles
 The results generated can also be used                            Singen)
  when it comes to investing in new assets.
 Demonstrable and transparent reductions in                   For further practical examples, please refer to
  overall energy consumption can be                            the Xing discussion forum on "Efficient Energy
  achieved in certain areas.                                   Management         at     Companies        and
                                                               Administrations".




Expert advice
Practitioners offer several tips and suggestions
for implementing a corporate energy analysis.

Some of these are shown below:

   “You need several people who really
    support and promote the whole thing!”
    Ulrich Leutgeb (WKW Automotive)
   "It's no use telling production what they
    have to achieve. The only function of
    management accounting is to create and
    communicate transparency. Production
    itself must decide what makes sense and
    what doesn't. At the end of the day,



                                                            10
     T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
T.A. Cook Research & Studies
Beside the Insight Report T.A. Cook Research & Studies offers studies in the area of Asset
Performance Management.



Current studies:

   Technical Services for Turnarounds in Petrochemical
    Plants in Germany, Austria & Switzerland
    (540 pages, 4400€)

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    (190 Pages, 1500€)

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    Maintenance (177 Pages, 2900€)

   Technical services for Turnarounds
    in petrochemical plants Western Europe (5900€)

   TAR Scheduling | Scheduling Practices for Turnarounds
    (1700€)




Exclusive studies and surveys as the basis for your decisions

Clients with specific questions related to topical issues or competitors may be best served by a single-client study.
With these studies, T.A. Cook Research & Studies offers you the opportunity to specify content and scope tailored
to meet your company's particular needs. Our team will be glad to put together a non-binding quotation for you
based on a pre-defined scope.




        T.A. Cook Research & Studies

        Leipziger Platz 2 | 10117 Berlin |
        Phone +49 (0)30 88 43 07-0 | Fax +49 (0)30 88 43 07-30
        E-Mail: studies@tacook.com

        The Research & Studies division conducts detailed market and company analyses in the area of Asset
        Performance Management. The focus of the team is to systematically investigate and clarify current mar-
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        base of specialised knowledge, which can be applied to each study as needed.




                                                                   11
            T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
Author: Mateus Siwek
                          Mateus Siwek, Studies Project Manager at T.A.                           Contact
                          Cook & Partner Consultants GmbH, is responsible                         E-Mail: m.siwek@tacook.com
                          for the preparation of market studies and anal-                         Phone: +49 (0)30 88 43 07-0
                          yses in the field of asset performance manage-
                          ment. Before that, he worked in the utility unit of
                          a market research company and has co-authored
                          several studies.




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If you have questions or suggestions about this or future Insight Reports we look forward to your call or mail:
T.A. Cook Consultants | Leipziger Platz 2 | 10117 Berlin | Tel.: (030) 88 43 07-0 | Mail: service@tacook.com

T.A. Cook is a management consulting firm focusing on Asset Performance Management with offices in Berlin, Birmingham, Houston,
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INSIGHT REPORT Energy Efficienc

  • 1. ENERGY EFFICIENCY AND ENERGY MANAGEMENT IN INDUSTRIAL COMPANIES
  • 2. Editorial ENERGY EFFICIENCY AND ENERGY MANAGE- MENT IN INDUSTRIAL COMPANIES Many industrial companies are increasingly focusing on energy efficiency as a way to be sustainable. This Insight Report addresses this issue and explores a subject which is still new ground for many companies. When it comes to energy efficiency, much de- pends on a company’s ability to identify new From disposal to utilisa- approaches. Saving energy is not that difficult if tion plenty of energy is being wasted. This explains the scepticism among some experts about com- Just like the waste disposal industry, many panies purchasing "green" energy. Most indus- companies will also have to reinvent themselves try representatives consider this to be the with a view to energy efficiency. Although the wrong approach. They claim that it is much physical items to be disposed of have not more important to stop wasting energy in order changed, they are now referred to as ‘secondary to boost one's own energy efficiency. raw materials’ in a recycling industry. The dra- matic change in this industry is a good example of how the use of resources is developing in Germany and the EU. The main objective is to generate maximum value from the use of a particular resource, be it a secondary raw mate- rial or energy. Just as with physical waste re- processing, the key question now is how energy can be retained or re-used. This question does not just extend to manufac- turing plants, but also to utility companies, where the first signs of significant energy saving are being seen. Most power stations in Germany and elsewhere operate cooling towers or cooling basins. What people perceive as rising steam is nothing but an enormous cloud of heat energy that is simply blown out into the atmosphere. Those who understand and accept this fact may come up with the idea of converting their own factory into a cooling tower in order to access this vast quantity of energy. Paper mills, for instance, are already adopting this method to feed their energy-intensive processes. Although this is a good energy supply concept, it is just the beginning of the possible value cycle. Another example from the waste disposal sector It is not particularly difficult for many companies might serve to explain this approach in more to increase their energy efficiency. This begins detail. Let us look at the paper industry, which when companies realise that their plants dis- today is intrinsically linked to waste disposal and charge energy, for example as heat, into the recycling. Since the introduction of recycled environment. This is an issue that has been paper, the value chain of this resource has wit- somewhat neglected up to now. We often treat nessed dramatic progress. Whilst the only dis- energy in much the same way as we did domes- tinction made in the early days was between tic and industrial waste just a few years ago, paper and recycled paper, companies today considering it as nothing but a byproduct to be distinguish between around 15 types of recycled disposed of. For business as well as environ- paper. Each of these varieties represents a spe- mental reasons change is necessary and will cific grade of this raw material. The original happen. resource - wood fibre – now has a spiral-shaped 2 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 3. product life cycle. In this cycle, the had major repercussions on com- spiral turns 15 times before the panies' efforts to boost efficien- original wood fibre can no long- cy. Now that energy prices are er be used. The end of the picking up again, the energy spiral is marked by ‘thermal utilisation’ – burning - when efficiency issue is once again energy is recovered from entering centre stage for busi- the residual fibre. Com- ness leaders. pared to this, the use of a power plant’s residual energy One can generally identify sev- in the example mentioned eral elements that can be used to above represents just two cy- boost corporate energy efficien- cles in a value spiral – the ener- cy. Besides almost trivial things, gy being used once at the power station and ‘recycled’ once when the paper mill such as managing the lighting uses its residual steam as an energy source. or heating of business premises, ener- However, here are potentially a much larger gy efficiency extends to the production process number of re-uses conceivable. as well as the use of residual energy (energy recovery). Companies active in this field have Economic efficiency and already adopted a very proactive view of these sustainability elements. Companies will now also find it worthwhile to consider the engineering of their Some companies have taken to heart not only own plants, their production processes and even the economic benefits of energy efficiency, but their own products’ construction in light of the also the role of sustainability. Environmental energy efficiency issue. responsibility and business reputation have an important role to play in this area. This is why Many energy efficiency measures do not even companies are at times exploring projects where require a budget to be implemented and pay off the return on investment takes five years or from the very first day. The only questions to be more to materialise. However, energy cost re- answered are: "To what extent are companies ductions remain the driving factor. Not surpris- willing to give priority to energy efficiency?", ingly, there has been a strong correlation be- and "What approaches will they adopt?" tween energy efficiency and the global econom- ic crisis in recent years. Slumping energy prices CONTENTS Energy efficiency and energy management in industrial companies ............................................. 2 Seven steps to improving energy management at companies ...................................................... 4 Energy efficiency regulation tightens ......................................................................................... 5 16001 – and what comes next? ................................................................................................ 6 Internal and external influences in coming years - act vs react .................................................... 7 Energy efficiency analysis in practice ......................................................................................... 9 3 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 4. Parameters of energy efficiency Seven steps to improving energy management at companies The discussion about the optimum energy use and the projects that have been implemented so far are so different that they show several approaches are available when it comes to boosting energy efficiency. The following discussion provides an overview of the individual steps to energy efficiency and optimisa- tion. Energy efficiency often starts with a company's of measures. The steps towards energy executive management. Work on energy efficiency are as follows: efficiency, however, often starts at middle management. Companies usually appoint an I. Identify waste: Where is power used un- energy efficiency officer who often lacks necessarily? detailed knowledge of the subject. The typical II. Avoid a throw-away mentality: How can residual energy be put to good use? III. Load management: How can the compa- ny or its production processes realistically be organised to reduce peaks in energy demand? IV. Production efficiency: How can plants and production lines be operated in the most energy efficient manner? V. Machinery efficiency: Which machinery is the most energy efficient available? VI. Process efficiency: Which production method minimises energy consumption in mak- ing the product? VII. Product efficiency: How can I design my product in an energy-efficient manner? Each of these steps can be considered and ap- plied individually. However, in practice most companies initially consider energy recovery and approach is to take a simple look at energy preventing energy waste before other steps are efficiency measures available to a company. On taken. the basis of the measures already implemented by active companies, seven steps can be identified which serve as the basis for a range 4 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 5. Legal framework Energy efficiency regulation tightens Besides rising energy prices, legal requirements and regulatory mechanisms can also drive energy efficiency measures. There are several plans to regulate energy use on a German and EU level. „Political, social and environmental influences the conditions for payment of the incentive in force you to address the issue of energy man- the US was the purchase of a low-consumption agement." Dr. Jörg Meyer (Head of the Energy car model. This also offered an enormous & Climate Protection Unit, Siemens AG) competitive advantage for companies which had embarked on efficient models at an early stage. This statement suggests that, in addition to This shows that energy management can be social influences and environmental aspects, considered as a competitive advantage. political conditions will also become increasingly demanding. Apart from DIN EN 16001 and ISO "Energy management saves time so that 50001 standards (the subject matter of a companies are able to act rather than merely separate article in this Insight Report), the first react," notes Dr. Jörg Meyer. far-reaching interventions have already been made in one of industry’s sovereign areas: It seldom makes sense to lag behind official Dr. Jörg Meyer, Head of the Energy & Climate Protection Unit, Siemens AG product design. A widely known example is the rules. The current reluctance to implement the gradual implementation of the ban on energy- EU's energy goals suggests that regulations will inefficient light bulbs. With this regulatory become even more restrictive. Therefore an intervention the issue of product efficiency, long active energy strategy can only be neglected by many companies, is increasingly advantageous. significant. Pressure on other industries is also growing. The automotive industry has already committed itself to greater transparency in its energy consumption. Pressure from the consumer end has also increased significantly in recent years. This step seems to be long overdue considering that an energy consumption limit has been in use for several years in the electronics industry. In the automotive industry’s case it was in fact the US which pioneered regulation, where the "cash for clunkers programme" proved to be a trailblazing concept. Unlike in Germany, one of 5 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 6. Legal framework 16001 – and what comes next? No - this is not an outlook to the year 16001. Instead, it refers to the imple- mentation of the DIN EN 16001 standard for energy-intensive companies. It should not be long before this standard is implemented because it is currently triggering many questions for businesses. One particularly important question concerns the features of an energy management system that is certified ac- cording to DIN EN 16001. "16001 merely sets the system certified. It can be basic parameters. It is left achieved either through a to the companies them- functioning environmental selves to decide how to management system that is implement these parame- certified according to ISO ters. A car maker will ap- 14001 or through an eco- proach this issue differently management and audit from, say, a fan manufac- scheme (EMAS). The third turer." Sylvia Wahren option is the provision of proof (Fraunhofer Institute for in another suitable form. This Manufacturing Engineering is contingent upon appropriate and Automation, TEEM) data capture as well as evalua- tion of the savings potential This statement summarises according to ecological and the underlying idea of this economic criteria. Since 1 July standard. 2009 marked the 2009, the DIN EN 16001 beginning for energy- standard has been offering intensive companies. Since companies the ability to certify then, they have been able their own environmental man- to benefit from a compen- agement systems. The stand- sation rule via the Renewa- ard sets out the framework for ble Energies Act. The legis- such a system. Furthermore, lator has made this benefit DIN EN 16001 is also a good contingent upon the intro- basis for companies when it duction of an EnMS (energy Sylvia Wahren, Fraunhofer Institute for Manu- comes to obtaining future management system). facturing Engineering and Automation, TEEM certification according to the Companies consider this international requirements of aspect to be the most diffi- ISO 50001. cult issue because such a system must be certified. Although regulators have Readers interested in more granted relatively ample lee- detailed information in this respect are well way, there is still a high degree of uncertainty advised to take a first look at the guide for among companies who do not yet know what companies and organisations published by the features an energy management system must German Federal Environmental Agency (DIN EN have in order to qualify for additional DIN EN 16001: "Energiemanagementsysteme in der 16001 certification as an environmental man- Praxis"; source: www.umweltbundesamt.de). agement system. In addition, there are only a Many questions are answered there. few systems available that can be implemented "out of the box" and already include certifica- The Renewable Energies Act offers three differ- tion. ent ways of having an energy management 6 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 7. Influence parameter Internal and external influences in coming years - act vs react Corporate energy efficiency and energy management are subject to a host of influences. Besides energy costs as the most important influence, further ex- ternal and internal forces influence the development of this issue. Experts agree on one point: There will be strong impact on the development of corporate energy demand for energy efficiency measures in the efficiency. Other influences include an increas- years to come. ing scarcity of raw materials, new production methods, more efficient processes and the cost Many companies already regard energy of replacements. management as a competitive advantage. This not only applies to competition between the All companies are equally exposed to these individual players on the market; energy factors, no matter whether or not a company has an energy management system. The question is not so much whether a company will address the energy issue but when this will happen. A company’s strategy might be active or reactive to circumstance; either strategy can be right or wrong. Simply put, an active strategy is, for instance, chiefly suitable for energy- intensive companies and not for companies where energy is a relatively minor cost item. The latter can afford to merely respond to regulatory intervention and hence to limit their action to what is absolutely necessary in this respect. The pressure to- wards efficiency puts an additional burden on small energy consumers whilst energy-intensive efficiency also has a companies can use it as a new way to play an role to play when it comes to competition active role in the market. The pioneers will inev- between geographic areas. Energy efficiency itably force the field to follow suit. can also prevent sites from losing their competitiveness to competitors in low-wage countries. The competition factor consequently influences a company's energy management strategy not just through internal, entrepreneurial interests, but also through external influences. It goes without saying that the legal conditions mentioned earlier also constitute an important external factor. Just like energy prices and com- petition, the legal framework also has a positive 7 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 8. On Demand Technical papers available on demand More detailed technical papers on corporate energy efficiency and energy management are now available on demand. Selected technical papers presented by leading companies at our technical conference on "In- dustrial Energy Efficiency and Energy Management", 27 to 28 October 2010, were rec- orded live. Did your schedule prevent you from attending our event, or do you want to revisit selected talks? With our "On-demand special", we give you the opportunity. Make use of this opportunity, and you will also receive the digital conference material (on CD) in addition to your personal access to the recorded talks. Under the following link www.UnityLivestream.com/TACookDemo you can examine the record- ing quality and view short clips from some papers. 8 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 9. Energy efficiency analysis Energy efficiency analysis in practice Before implementing an energy management system, a company should first perform an efficiency analysis. WKW Automotive and Amcor Flexibles Singen are good examples of successful implementation projects. WKW Automotive (aluminium processing) and Furthermore, an efficiency analysis can also Amcor Flexibles Singen (manufacturer of help to identify incorrect energy bills. primary packaging) are demonstrating how an efficiency analysis can be successfully carried out. In WKW's case, a successful implementation enabled a return on investment for the entire project in eight months. Careful performance of an analysis can be the foundation for a quick return on investment. Different approaches can be taken for an analysis. Many companies, for instance, rely on their own, company-specific solutions. Other companies, such as Amcor Flexibles Singen, rely on standard methods, such as Six Ulrich Leutgeb, WKW Automotive Sigma in order to analyse their energy demand. A sound database is vital in either case. Companies first need to identify their energy consumption from different sources and How can an analysis cause integrate these into an energy data management system. Every significant energy changes in load distribu- load should be fitted with a dedicated metering tion? unit; measurements at fifteen minute intervals tend to work well for tracking load curves. Many WKW learnt from its efficiency analysis that the companies need to invest in an IT infrastructure energy consumption of a plant or line is composed of meters and data capture points. dependent not just upon the load (i.e., the plant This may well mean a five-digit investment. But or line), but also upon the product that is such an investment can pay off even if no currently being manufactured. WKW Automotive energy is saved at all. quotes two practical examples: In the case of WKW, for instance, an analysis enabled a better distribution of the company's Curing ovens energy load curve so that peak load demand could be reduced. If a company manages to "Certain products need more energy than others reduce its peak load by one MW through in the oven. Once we understood this, changing its load distribution pattern, this production of energy-intensive products can be generates savings of around €7,000 per month shifted to the night shift when energy is cheaper without a reduction in energy consumption. This and the load curve low. However, the human peak load reduction also generates a certain factor is important here. It would be no use if all measure of sustainability. The price of energy in the ovens entered the heating-up phase Germany could be significantly reduced if simultaneously. Needless to say, they have to companies managed to handle their peak loads start in succession” Ulrich Leutgeb (WKW better, as utilities’ activities to balance peak Automotive) loads are a particularly significant cost factor. 9 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 10. Extrusion presses delivering to customers is what matters. The onus does not have to be left entirely "Certain alloys require more power in the press. These alloys were previously often produced during the day. Without an energy management system, this consumption would not have been visible” Ulrich Leutgeb (WKW Automotive) These two examples show to what extent an efficiency analysis can affect operational structures and the possibilities which this opens up for companies. With such an analysis, WKW Automotive managed to optimise its own production without changing the product or delivery times. At Amcor Flexibles Singen, an analysis formed the basis for Peter Ritter, Amcor Flexibles Singen redesigning and optimising the factory's entire lighting system. to production. As soon as consumption is The benefits at a glance transparent, they will develop their own ideas and identify their savings potential." Apart from the above-mentioned benefits of an Ulrich Leutgeb (WKW Automotive) analysis, further advantages include:  "You do not always need direct KPIs for Six Sigma. You may also use somewhat less  The introduction of the energy exact KPIs as long as there is enough management system leads to a clearly potential because you can achieve a lot in reduced load curve. The peak load can be this way.” Peter Ritter (Amcor Flexibles reduced by more than 10%. Singen)  The measures described enable a significant  “Quick wins are possible even without Six reduction in the price per kWh. Sigma.” Peter Ritter (Amcor Flexibles  The results generated can also be used Singen) when it comes to investing in new assets.  Demonstrable and transparent reductions in For further practical examples, please refer to overall energy consumption can be the Xing discussion forum on "Efficient Energy achieved in certain areas. Management at Companies and Administrations". Expert advice Practitioners offer several tips and suggestions for implementing a corporate energy analysis. Some of these are shown below:  “You need several people who really support and promote the whole thing!” Ulrich Leutgeb (WKW Automotive)  "It's no use telling production what they have to achieve. The only function of management accounting is to create and communicate transparency. Production itself must decide what makes sense and what doesn't. At the end of the day, 10 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 11. T.A. Cook Research & Studies Beside the Insight Report T.A. Cook Research & Studies offers studies in the area of Asset Performance Management. Current studies:  Technical Services for Turnarounds in Petrochemical Plants in Germany, Austria & Switzerland (540 pages, 4400€)  How companies use RFID in maintenance (190 Pages, 1500€)  Offshore Wind Farm Operations & Maintenance (177 Pages, 2900€)  Technical services for Turnarounds in petrochemical plants Western Europe (5900€)  TAR Scheduling | Scheduling Practices for Turnarounds (1700€) Exclusive studies and surveys as the basis for your decisions Clients with specific questions related to topical issues or competitors may be best served by a single-client study. With these studies, T.A. Cook Research & Studies offers you the opportunity to specify content and scope tailored to meet your company's particular needs. Our team will be glad to put together a non-binding quotation for you based on a pre-defined scope. T.A. Cook Research & Studies Leipziger Platz 2 | 10117 Berlin | Phone +49 (0)30 88 43 07-0 | Fax +49 (0)30 88 43 07-30 E-Mail: studies@tacook.com The Research & Studies division conducts detailed market and company analyses in the area of Asset Performance Management. The focus of the team is to systematically investigate and clarify current mar- ket concerns and requirements as well as anticipated developments and their consequences for market players. As well as studies on topical issues, we compile trend reports and continually expand our data- base of specialised knowledge, which can be applied to each study as needed. 11 T.A. Cook Consultants Insight Report 02 – 12/2010 | Energy efficiency and energy management in industrial companies
  • 12. Author: Mateus Siwek Mateus Siwek, Studies Project Manager at T.A. Contact Cook & Partner Consultants GmbH, is responsible E-Mail: m.siwek@tacook.com for the preparation of market studies and anal- Phone: +49 (0)30 88 43 07-0 yses in the field of asset performance manage- ment. Before that, he worked in the utility unit of a market research company and has co-authored several studies. Insight Report is a service of T.A. Cook If you have questions or suggestions about this or future Insight Reports we look forward to your call or mail: T.A. Cook Consultants | Leipziger Platz 2 | 10117 Berlin | Tel.: (030) 88 43 07-0 | Mail: service@tacook.com T.A. Cook is a management consulting firm focusing on Asset Performance Management with offices in Berlin, Birmingham, Houston, London, Raleigh und Rio de Janeiro. The core competence of the consulting business is the sustainable implementation of asset, opera- tions and service-oriented excellence. As a change management specialist, the firm delivers measurable value enhancement and bot- tom-line productivity gains. In order to achieve these results T.A. Cook offers a wide range of professional services which ensure that all business processes – from strategy definition through management to organisational design – are effective, efficient and sustaina- ble. Complementing the consulting business, the T.A. Cook Academy has become a leading organiser of international conferences and seminars relating to Asset Performance Management. Annual events include the MainDays summit as well as conferences centred on topics such as Shutdowns & Turnarounds and Capex Management. T.A. Cook’s clients are typically businesses, their suppliers and contractors working with significant industrial assets across multiple sectors. The company has particular expertise in the petrochemi- cals, plastics, pharmaceutical, transport, mining and food sectors as well as excellent knowledge of regulated environments occupied by gas, water and electricity utilities. You will find further information at: www.tacook.com