Celestica
Topic:
Achieving Energy and CO2 Savings Through Multiple Initiatives.
Synopsis:
Celestica Galway introduced a series of over 23 initiatives to reduce the CO2 footprint through energy
By following and aligning with the production cycle the team introduced changes to test ‘set up’ projects before introducing them to existing production lines. With help of team leads they were able to seamlessly introduce the changes. Communication was critical to the success of the projects along with starting with small changes at first before building on these success of these for larger scale projects.
Casestudy:
Problem Statement/Challenge
The Galway plant was tasked with reducing its energy consumption, CO2 emissions footprint and achieving cost savings, in line with the Celestica Global policy goals. It also had to ensure that projects did not have an impact on production and captured the ‘buy-in’ from staff at all levels.
Solution Implemented
Rather than one single initiative, a wide range of site wide programmes were introduced at various levels, which captured the support of staff and positively impacted on the over on key energy targets.
- Production floor lighting (timers only)
Installation of simple 3 channel timers on the two main lighting fuse boards to allow the lighting to be timed to suit the production patterns, the additional boost buttons give flexibility to all if overtime or weekend production is required. Strong positive saving were realised here.
- Task and bench lighting CTO business unit (timers and LED)
Replaced the original 4 foot twin fluorescent which were left on 24/7 with an LED and a rewired system that each bench could be controlled separately by team leader. Give greater flexibility on the control of work stations compared to all on and no production requirement.
- Task and bench lighting DDA business unit (timers and LED)
Installed LED’s on the benches and the task areas in new production set up with 2 hour boost timers to prevent the lights being left on in an area where not required.
- All office, reception and canteen lights to LED’s (139 in total)
Conversion of 4 by 22 watt fluorescent lighting to 30 watt LED’s in all areas. Light are on for 12 hours per day, 6 days a week, 52 week in the year.
- Changed all external lights to LED’s
Conversion of variety of external lights to LED’s, better quality light for access and CCTV footage.
50% reduction in kWhrs, payback less than one year.
- Installed M2G system on two oil burners
Monitoring the return temperature to the boiler and holding out the boiler until a drop in the temperature is reached. This improves the boiler efficiency and reduces the consumption in oil use.
- Installed a boost button in BMS for AHU’s and timed to suit production
This gave better control of AHU’s as they were being left on 24/7. This boost can be used similar to the lighting boost to follow production overtime and end of quarter ramp in business.
- Installed meters in lighting boards prior to running RFQ for LED conversion
This will show exactly the current running costs to the whole factory floor of the existing lighting and be able to be compared to the new install. This is great as it engages with the all employees and gets them interested in energy saving and reduction.
- VSD’s installon AHU’s
Variable speed drives installed on 4 Air handling units, varying the frequency to the existing motors. Will have to be monitored to see the paybacks and kWhrs savings.
- Plans to change to natural gas from oil in the heating system
A feasibility study was carried out and there is gas in the park and passing by our two buildings. This looks a good move but trying to get all the associated costs together to present to finance to show savings and payback.
- Plans to upgrade chillers
These are 17 years old and are in need of a serious rebuild or replacement. I have a feeling that they are oversized and seeing as there are only used for a short period of the year it is hard to get the financial backing in a format that will show payback and would reach out for advice on this one
- Solar panels on the roof of Building 2 is a viable option
In talks with our new landlords on the ideal location of the roof and lack of plant on roof in building 2. We have had a site survey from Kingspan ESB funded solar.
- Installed a VSD compressor in 2015 and have now got a data live link to track use
Air is one of our big energy users and looking at some form of shut offs for the production floor when not in use to prevent the air leaks
Installed a remote program to monitor the usage and a text alert on the failure of the variable speeds as the old less efficient are on standby and could be running unaware to facilities.
- On request of Customer installation of an insulated wall instead of security bars.
Our customer requested that we secure our existing comms room with bars on the external windows. What we proposed was to erect a stud wall the full height of the window and to use spray insulation on the internal stud. The studded wall and insulation did secure the comms room to customer requirements and improved the u value of the room which has an air con unit running full time to keep the room temperature at 24 degrees Celsius. It also reduced the u value from solar gain blocking out the windows.
- Undertook a ultrasonic compressed air leak detection survey
The first survey we took was on the supply of the compressed air, this was done over a Christmas shut down. We surveyed where the leaks were and turned off supplies to the machines in the plant. Over the first 3 days we monitored the usage. The next few days we repaired the leaks and the turned on the compressor and monitored again for 3 days over New Year.
The savings were roughly 10% of use of annual compressed air usage.
The second survey was taken out on the actual production machines and shows that another 10% can be realised.
- Installed alarms on fuel oil bunded tanks
Oil tanks were installed with 110% bunded tanks underneath in the event of tank failure. We installed float switches to an alarm that allows us empty the bunds once filled up with rain water. This has proved very useful as it allows us to use the bund as intended as the rain water was taking up most of the capacity.
It also alerts us if the tanks ever did fail so we can react appropriately.
- Complete ban on non-recyclable cups in site canteen
In 2017 we used almost 77,000 cups on the site resulting in 1.4 tonnes of waste, they cost … We provided all staff with a branded recyclable cup and was a huge success.
- VSD vacuum pump installed
A new VSD vacuum pump was installed with an average 70% saving compared to the old one. A heat exchanger was also fitted and runs smother to the production line than the previous pump.
- TRV on all radiators
Fitted all radiators with thermostatic controls so they can be turned on and off locally.
- LEDs in building 1
Converted the 418 lighting fixtures to LEDs with a total of 20% in total energy consumption.
A very interesting program with a lot of vendors with completely different financial options and proposed savings.
- Timber pallets for recycling
A total of 124,500 kg of timber pallets recycled with a cost avoidance from our waste contractor of 17,100 euros.
- Helium reduction
Records were maintained and we upgraded our pipes and valves and showed a 20% reduction in each helium bottle.
- Heat exchanger on compressors and vacuum pump
Heat exchangers were installed in the compressors and the vacuum pump and the heat was transferred into out heating system. The only glitch is that the heat exchanger on the heating side is not big enough and placed in the wrong place in the system. We have plans with our heating contractor to remedy and achieve more heat transfer for the exchangers.
Results Achieved
Monitoring of the impact of some the programmes is still ongoing but some individual impacts are:
- External LED lighting replacement lead to 50% reduction in kWhrs, payback less than one year.
- Savings of 10% of use of annual compressed air usage
- New VSD vacuum pump delivered average 70% saving
- LEDs gave a total of 20% in total energy consumption
- A total of 124,500 kg of timber pallets recycled with a cost avoidance from our waste contractor of 17,100 euros.
- upgraded our pipes and valves and showed a 20% reduction in each helium bottle.
- Ban on non-useable cups saved 77,000 single use cups on the site resulting in 1.4 tonnes of waste
Additional impacts were also experienced including:
- A large change in all employees attitude to energy use.
- Active engagement from all levels in the company opening the door to more positive changes.
- Change in organisational mind-sets/culture with energy and CO2 savings becoming a hot topic of discussion within all levels
About Gabriel Corless:
About Celestica Galway:
Celestica’s Galway (& Leixlip), Ireland facilities specialise in high-volume manufacturing and assembly on high-precision automated lines. The Galway (& Leixlip) facilities are a key provider of the company’s Automated Manufacturing Services offering.
The sites have strong technical capabilities in the areas of automation, plastics, vision systems, ultrasonic welding, traceability systems and Programmable Logic Controller programming.
The highly skilled teams are experienced in designing, installing, commissioning, operating and optimizing automated manufacturing lines on behalf of their customers across a wide range of industries.
Celestica’s Galway & Leixlip teams have particular expertise in the integration of plastics, metals and electronics for such products as medical devices and printer consumables.