fitesa case study january 18, 2012

Fitesa Case StudyJanuary 18, 2012

CONFIDENTIAL – 2

Case Study - FitesaWho is Fitesa?

• 11 production sites globally• 2nd largest Nonwoven Manufacturer in the world• Locally - Washougal, WA since 1982

• Present Employees: 50• Products: non-woven fabric rolls

• Fabrics composed of PP, PE, PET, PLA, Green PE, Adflex

• Washougal site originally designed for three energy intensive non-woven fabric lines.

• Downsized to one retrofitted production line.• Most of energy consumption from original lines came from air

usage. • Energy Program evolved from capital projects to an energy

management process.

CONFIDENTIAL – 3

CONFIDENTIAL – 4

Large Extruder

s

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Spinning PackFace

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Production Line

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Slitting To Customer Rolls

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Case Study – Fitesa – Phase 1

Lighting Capital Project• Warehouse, shop, prod. areas• Old

• Metal halides, T12 fluorescents• 24 hours, 7 days per week

• New• 6 & 4 lamp T8 high output, high bay• Fixture mounted occupancy sensors• Energy savings: 542,000 kWh/yr• Cost savings (kWh, kW): $28,500/yr• Project costs: $98,500• Incentive: $34,500 • Payback: 2.2 years

CONFIDENTIAL – 99


Compressor Capital Project

• New line required less pressure, capacity

• Baseline• One 600 hp centrifugal• 100 psi• 2,500 cfm• Blowoff valve control• 24/7

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Case Study - Fitesa

New Compressors

• New• Two 250 hp oil free screw compressors, load - unload, lead - lag• Energy savings: 2,000,000 kWh/yr• Cost savings (kWh, kW): $94,000/yr• Project costs: $490,000• Incentive: $146,000• Payback: 3.7 years

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Chilled Water Capital Project• Retrofitted line requires less cooling capacity• Old System

• (1) 300 hp closed loop circulation pump• (1) 125 hp cooling tower circulation pump• (1) 40 hp chilled water pump• (2) cooling towers

• 10 hp fan motors• (1) 200 ton chiller

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Closed Loop Chiller Project

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Case Study - Fitesa

Chilled Water System• Retrofitted line requires less cooling capacity. Went to Closed

Loop systems.

• Power reduced by ~400 hp• Smaller pumps• (3) 75 ton chillers• Extensive re-piping• Energy savings: 2,600,000 kWh/yr• Demand savings: 300 kW/month• Cost savings (kWh, kW): $103,600/yr• Water, Sewer, & Chemical Savings: $140,000• Project costs: $930,000• Incentive: $650,000• Payback: 1.3 years

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• HPEM (High Performance Energy Management)• Started Program June 17, 2010• 5 year long continuous improvement process• Regional collaborative effort• Fits well with existing culture of continuous improvement

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Formation of an HPUM Team

Form a High Performance Utilities Management Team that has representatives from all functions in the plant.

HPUM Core Team Members HPUM Sponsor Dave Rohrbach Plant Manager Energy Champion JD Hisey Continuous Improvement Manager Key Team Members Doug Moore Mechanic

Chuck Bales Electrician

Gary Jones Maintenance Supervisor

Ray Mangs Operations Manager

CONFIDENTIAL – 16

Fitesa’s Global Mission and Vision

Fitesa’s MissionAdd value to Customers, Shareholders & Team by providing high quality products with exceptional service. We will do so by proactively reducing our carbon foot print through better processes and product development.

Fitesa’s VisionBe the preferred choice for the supply of spunmelt, carded and air-laid nonwoven fabrics to the Global Hygiene market.

CONFIDENTIAL – 17

Develop Plant Policy, Metrics, & Goals

Fitesa Washougal’s Utility Usage PolicyFitesa Washougal will continuously look for ways to reduce our usage of utilities so that we continue to support our environmental and cost strategies in a way that is consistent with our global vision.

Fitesa Washougal’s Metrics For electrical energy, our metric is kWh/kg of saleable product

produced. For water consumption, our metric is gallons of water purchased/kg

of saleable product produced. For water outfall, our metric is gallons discharged/kg of saleable

product produced. For natural gas, our metric is therms/day.

Fitesa Washougal’s GoalsFor each element of our utility usage, Fitesa Washougal’s goal is a 5% decrease in each metric per year.

CONFIDENTIAL – 18

Create an Opportunity Register Meet with all plant personnel. Educate them on the mission

and goals of the HPUM Team. Ask for their ideas to reduce our carbon footprint.

As a HPUM team, created initial list of utility saving ideas.

List included all ideas. They are then prioritized.– Some go into Project Hopper and become Capital projects for coming

years.– Most ideas will be non-capital projects. The highest priority items

will be on a Fitesa Action Plan, the rest left on the Opportunity Register.

CONFIDENTIAL – 19

Example of Opportunity RegisterOpportunity

# Date Type Submitted By Present Situation Idea Implementation

Date

HPUM0001 7/16/10 E Shelley F.Air Conditioners in Office - Cool at 74 degrees F, heat at 72 degrees F all

the time.

For offices, lower set points for cooling to 76 degrees F during occupied times, 85degrees F for unoccupied times. For

Heating, lower to 70 degrees F for occupied times, 55 degrees F for unoccupied times

7/16/2010

HPUM0002 7/16/10 E Connie C. Air conditioner runs full time in the Laminator/Documents Room

Transfer Laminator and documents to an empty office on 2nd floor and turn off or eliminate the air conditioner.

HPUM0003 7/16/10 E Connie C. Air conditioner in the exercise room gets left on all the time

Install a timer switch so the air conditioner shuts off after a period of time once activated. Ended up setting AC at 81

degrees. Shutting off would cause excessive failure of AC.

10-Sep

HPUM0004 07/16/10 E Albert Linde Room - Lights are on all the time

Repair the Motion detectors in the Linde room

HPUM0005 07/16/10 E Albert RT Switch Room has lights on all the time

Put a motion sensor in the room so that only come on as needed or at least shut off whenever leave the room

HPUM0006 07/16/10 NG AlbertHeater in the Surfactant room is set

for 72 degrees and control is unstable

Determine lowest set point needed for the room, then control room to that temperature. Best temp determined to be 60

degrees. Thermostat set.18-Oct

HPUM0007 07/16/10 E Tom S. Railcar loaders running more than they need to

HPUM0008 07/16/10 E Steve S. Lights are always on in the welding shop/roll storage area

Put lights on motion detectors or a program

HPUM0009 07/16/10 E Tom S. Candle Filter oven on 4th floor is on all the time at 600 degrees.

Lower temp to 400 degrees 25-Jul

HPUM0010 07/16/10 E JD Light in minilab on at all time. Air conditioner set at 65 degrees F.

Put motion detector on lights. Lock air conditioner controls at 75 degrees.

HPUM0011 07/16/10 E JDLights in old foreman's office on at all

times. Air conditioner set at 65 degrees.

Put motion detector on lights. Lock air conditioner controls at 75 degrees.

HPUM0012 07/16/10 E JD

Many lights on at all times on 2nd, 3rd, 4th floors in old line 1 & 2 areas. Lights on at all times in old L2 gun

bridge. Air conditioner on.

Remove or put motion detectors on all lights in old L1 and L2 areas. Remove all air conditioners on L1 and L2 gun bridges.

HPUM0013 07/21/10 E JDResin dryer turned on 24 hours prior to a PLA run, shut off at the end of

the PLA run

Turn on resin dryer 8 hours before a PLA run, shut off 2 hours before end of PLA run. 24-Jul

HPUM0014 07/21/10 E JDPack Ovens on at 600 degrees all the

time.

Keep pack ovens at 300 degrees all the time. Turn up to 600 degrees when know will probably need to install pack. First

step completed on 9/21 to set at 500 degrees.21-Sep

HPUM0015 07/21/10 E JDExtruder for Erema kept on at full

temp at all times

Turn down to 250 degrees?? if know that following shift will not run extruder. Turn back up to full temperature when new shift

comes on board to run Erema

HPUM0016 07/22/10 W AlbertToilets and urinals are high use

designs Install controls on Urinals and toilets so have lower flow options

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Connected loads to be determined

as needed and if helpful to

115 kV ( 8 units ) document actual energy usage4160V 480V for opportunity areas

Current/Projected State - 2010 Ancillary MeterREVISION DATE only $400/month charges Projected Use kWh per year - 18,850,000

$1,066,900

SUPPORT SYSTEMS and ACTIVITIESCOMPRESSED AIR HVAC - Trane Roof Top Units HVAC - Plant Air PANEL COOLERS PLANT LIGHTING(1) Kobelco 250 hp Units 1 - 15 First Floor 4160V unit 25- 30 units T5's with motion detectorsOperating Hrs/Yr ? A/C & some gas fire heat Motor hp 150 Total Motor hp 10 Recently upgraded - 2009

Tons of Cooling Operating Hrs/Yr ? Operating Hrs/Yr ?(2) Kobelco 250 hp Fan Motor hp 305Operating Hrs/Yr ? Operating Hrs/Yr ?

Upper Floors 4 systems

Plant Air - PSI 125 Motor(s) hp 155Equipped with VFDs Operating Hrs/Yr ?

Closed Loop H2O use Low

0% 0% 0% 0% 0%Estimate kWh / year 0 Estimate kWh / year 0 Estimate kWh / year 0 Estimate kWh / year 0 Estimate kWh / year 0

RAW MATERIAL - Plastic Pellets WEB PRODUCTION - primary value stream

Unload Rail Car Silo Storage Blend Extrude Candle FilterBlower Motor(s) Blower Motor(s) 6 units / 2 per beam 6 units / 2 per beam 6 units / 2 per beam

Compressed Air Use LowClosed Loop H2O Use Low

Dry Operating Hrs/Yr ? Operating Hrs/Yr ? Operating Hrs/YrFor PLA & PET Pellets Motor(s) name/hp 6 Motor(s) name/hp 1587.75Used 10%

Dry Temp 100 C

Electric Heat Electric Heat Electric Heat

0% 0% 0%Estimate kWh / year minimal Estimate kWh / year minimal Estimate kWh / year 0 Estimate kWh / year 0 Estimate kWh / year 0 Estimate kWh / year

Production Track - kg's input

Die Stage and Prep (2) Preheat Ovens 8.5Operating Hrs/Yr 24x7 Ultrasonic Bath Operating Hrs/Yr

Electrical Panels

Dies

Plant

07/02/10

Office and PlantMulti Locations-See Process Step Plant

Projected $/Year -

Main Service to PlantMultiple Sub Meters (Analog)

PLANT

Energy MapWashougal, WA Plant

ELECTRICITYClark Co. PUD

M

MDirect to 4160V Motors

One Power BillM

3

Beams

Create an Energy Map

CONFIDENTIAL – 21

Create Fitesa Action Plans

Metric: Reduction in Utility Usage

Responsible: JD Hisey

Effect Tactic Specific Action Tracking # Responsible Person Deadline Original

Deadline Done

Reduction in kwh usage from lighting improvements

Develop Lighting Reduction Program by section of plant

Develop plan to replace parking lot lights

Disarm 4th Floor Tower lights - 4 exterior lights 3G#534 GJ 5/1/11 5/1/11 3/25/11Fix lights in railcar area - disconnect cooling tower light

and repair photo cells on resin unloader area3G#535 GJ 5/1/11 5/1/11 4/1/11

Disconnect exterior light at surfactant storage area 3G#536 GJ 5/1/11 5/1/11 3/25/11Develop plan to replace exterior lights above 4th floor

towerRelight the new surfactant area to expected efficient

standard lighting3G#537 CH 6/1/11 6/1/11

Overbonder hot oil room - Lights only needed 2 days a month. Need off switch

GJ

Reduction in Kwh usage from improvements in motor effiiencies

Develop policy to replace and rebuild motors to be much more efficient

HPEM0020Purchase high efficiency vacuum motor 3G#538 GJ 5/1/11 5/1/11 2/1/11

Reduction in kWh usage by reduction in heating practices

Reduce Kwh used by Erema when not in use HPEM0015

Develop new SOP to shut off Erema extruder and air when not in use

3G#428 SS 4/1/11 4/1/11 3/22/11

Write critical SOP to the standard format. Audit against new Erema shutdown SOP to ensure compliance and that

training is adequate.3G#539 SS 7/1/11 7/1/11

Acquire an electrical usage meter so can measure usage and gather data for various machines such as Erema,

Pack oven, Candle filter oven, etc.3G#452 GJ 10/31/10 10/31/10 10/28/10

Fix Erema so that when you turn off power, need an electrician to reset

3G#429 GJ 3/15/11 3/15/11 3/15/11

Reduce temperatures in candle filter oven whenever possible

Look at cost of purchasing a much more efficient, properly sized candle filter oven HPEM0009

3G#431

Reduce temperatures in pack oven whenever possible

Develop new procedure for reducing pack oven temperatures. Test to see if can reduce to 500 degrees F

if use pack blankets. HPEM00143G#432 AW 5/1/11 5/1/11

Take initial step by reducing pack oven temperature to 500 degrees F

SS 9/21/10 9/21/10 9/21/10

Reduce Overbonder Heat-up time before an ATS run HPUM0023

Develop new procedure where overbonder is only turned on at the last possible moment before an ATS run. Write

procedure.3G#433 SS 4/1/11 4/1/11 3/15/11

Write critical SOP to the standard format. Audit against the ATS startup procedure to ensure compliance and

adequate training is in place.3G#540 SS 7/1/11 7/1/11

Reduce time resin dryer is on prior to a PLA Run HPUM0013

Develop new procedure where resin dryer is only turned on at the last possible moment before a PLA run. Need to

write procedure.3G#434 AW 4/1/11 4/1/11 3/15/11

Write critical SOP to the standard format. Train all folks against the PLA SOP and audit against it to ensure compliance and that adequate training is in place.

3G#541 AW 7/1/11 7/1/11

Reduce press roll temperatures Do study to determine possibilities of lowering press roll temperatures

3G#475

Reduce Air Compressor Usage and Pressures

Modify system so end of line has adequate pressure

Weld in new receiver tank connection to provide less constriction

3G#542 GJ 5/1/11 5/1/11 3/25/11

As air volume is inadequate in the packroom, explore idea of running a two inch line to the east maint shop and

possibly put a receiver tank there.Confirm the air pressure developed at the wrapper.

Determine pressure drop from compressor to wrapper.3G#454

Identify all of our Air Canaries. Complete a Compressed Air Map

3G#481

3G Report Concluded

On going

Delayed

CONFIDENTIAL – 22

Primary Tool - Conduct Energy Audits

Nine Energy Wasters–Unnecessary Running or Idling –Leaks–Pressure & Friction Losses–Sub Optimized Efficiency–Malfunctions–System Imbalance–Misapplication–Scheduling–Sloppy Processes (Not LEAN)

CONFIDENTIAL – 23

Develop Baseline CUSUMSUMMARY OUTPUT (6/6/09 - 6/19/10)

Regression Statistics

Multiple R 0.953579

R Square 0.909313 CV = 0.05

Adjusted R Square 0.905825

Standard Error 15851.33

Observations 55

ANOVA

df SS MS F Significance F

Regression 2 1.31E+11 6.55E+10 260.7015 7.87E-28

Residual 52 1.31E+10 2.51E+08

Total 54 1.44E+11

Coefficients Standard Error t Stat P-value Lower 95% Upper 95% Lower 95.0% Upper 95.0%

Intercept 134675.6 18994.51 7.090243 3.55E-09 96560.39 172790.9 96560.39 172790.9

X Variable 1 462.6536 39.45358 11.72653 3.21E-16 383.4842 541.823 383.4842 541.823

X Variable 2 -92141.2 24739.76 -3.72442 0.000483 -141785 -42497.3 -141785 -42497.3

CONFIDENTIAL – 24

CUSUM – kWh/Kg ProductionM

ar-0

9

May

-09

Jul-0

9

Sep-

09

Nov-

09

Jan-

10

Mar

-10

May

-10

Jul-1

0

Sep-

10

Nov-

10

Jan-

11

Mar

-11

May

-11

Jul-1

1

Sep-

11

Nov-

11

Jan-

12

Mar

-12

May

-12

Jul-1

2

(4,500,000)

(4,000,000)

(3,500,000)

(3,000,000)

(2,500,000)

(2,000,000)

(1,500,000)

(1,000,000)

(500,000)

-

500,000

CUSUM

CONFIDENTIAL – 25

Washougal Site HPUM Best Practices

Best Practices – turned into plant policy – will help leverage best use of existing technologies.

Plant Lighting– Delamp when not necessary

Air Compressor Optimization– Added another Receiver Tank– Reduced from 121 psi to 112 psi

Natural Gas Controls – Added controls in main building Calibration of Waste Water Outfall (Sewer) Meters Heating Practices

– Reduced heat up times for several operations– Shut off several operations when not in use

CONFIDENTIAL – 26

Electrical Usage - 7.6% reduction Year 1 HPUM –- 28.7% overall reduction

9/1/20

09

12/1/

2009

3/1/20

10

6/1/20

10

9/1/20

10

12/1/

2010

3/1/20

11

6/1/20

11

9/1/20

11

12/1/

2011

3/1/20

121.000

1.250

1.500

1.750

Electricity Usage

Kwh/kg Linear (Kwh/kg)

Month

Kwh/

Kg P

rodu

ced

CONFIDENTIAL – 27

On Peak Demand - $4.60/kw

Dec-09

Feb-10

Apr-10

Jun-1

0

Aug-10

Oct-10

Dec-10

Feb-11

Apr-11

Jun-1

1

Aug-11

Oct-11

Dec-11

Feb-12

2,000

2,200

2,400

2,600

2,800

3,000

3,200

3,400

On Peak Demand

On Peak Demand (kW) Linear (On Peak Demand (kW))

Date

kW

CONFIDENTIAL – 28

Natural Gas – 67.7% Reduction Year 1 HPUM

Sep-08

Dec-08

Mar-09

Jun-09

Sep-09

Dec-09

Mar-10

Jun-10

Sep-10

Dec-10

Mar-11

Jun-11

Sep-11

Dec-11

Mar-12

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

200.00

Natural Gas Usage

Month

Ther

ms/

Day

CONFIDENTIAL – 29

City Water Usage - 69% reduction Year 1 HPUM

Dec-08

Mar-09

Jun-09

Sep-09

Dec-09

Mar-10

Jun-10

Sep-10

Dec-10

Mar-11

Jun-11

Sep-11

Dec-11

0

200

400

600

800

1000

1200

City Water Usage

Gallons Used/MT Produced

Linear (Gallons Used/MT Produced)

Month

Gal

lons

Wat

er/M

T Pr

oduc

ed

CONFIDENTIAL – 30

Sewer Outfall – 94.6% Reduction Year 1 HPUM

3/1/20

09

6/1/20

09

9/1/20

09

12/1/

2009

3/1/20

10

6/1/20

10

9/1/20

10

12/1/

2010

3/1/20

11

6/1/20

11

9/1/20

11

12/1/

2011

3/1/20

120

500

1000

1500

2000

2500

3000

3500

4000

4500

Waste Water Outfall

Gal Outflow/MT Produced

Linear (Gal Outflow/MT Produced)

Month

Gal

lons

Out

fall/

MT

Prod

uced

CONFIDENTIAL – 31

Global HPUM Committee Created

Fitesa facilities will strive to reduce the amount of energy we utilize to produce our nonwoven fabrics through efforts of best practice sharing, trending of kpi’s and a continuous drive for improvement.

CONFIDENTIAL – 32

HPUM Committee Meeting Schedule

Coordinator: Dave Rohrbach(E) EnergyDate Time Place Brasil México Simpsonville Peru Washougal25-Feb 1PM EST Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey27-May 2PM ESD Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey19-Aug 2PM ESD Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey30-Nov 1PM EST Video conference Everton Cecconello Raul Darrel Dean Jameson Miguel JD Hisey

Invited: Flavio Tavaniello, Jose Luis, Stephen Middleton

Sponsor: Rene Ruschel

Members:

CONFIDENTIAL – 33

Plant Energy Metric Review – KWh/Kg

AVE10 Jan Fev Mar Abr Mai Jun Jul Ago Set Out Nov Dez0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

KWh

/ Kg

CONFIDENTIAL – 34

Plant Energy Metric Review – US$/Kg

AVE10 Jan Fev Mar Abr Mai Jun Jul Ago Set Out Nov Dez0.000

0.050

0.100

0.150

0.200

0.250

US$

/ Kg

CONFIDENTIAL – 35

The Future – Energy Management Plan Short Term – Early 2012

Add Operations Folks to HPUM TeamStrengthen Air Leak ProgramRegular Energy AuditsAdd Controls to Natural Gas Heating in Maintenance Shop AreasReduce Air Needed for Calendar Stacks and Motor Cooling

Medium Term - 2012Right Size Air Dryers Upgrade/Reduce Exterior LightingUpgrade Resin LoadersExpand HPUM to 6 new plants in Sweden, Germany, Italy, China and the USA

Long Term – 2013Implement Best Practices Identified at other Fitesa Plants