Case about Energy Savings
Case about Energy Savings
at Danfoss Compressors d.o.o. in Crnomelj, Slovenia FACTS
EnSave® Project Highlights May 2007 EnStudy® Analysis of energy consumption identification of potential savings
September 2007 Verification & Planning (3 months)
January 2008
EnSave® case in brief Environmental impact CO2 emissions reduction CO2 reduction “per employee”
5,200 tonnes p.a. 5.5 tonnes p.a.
Financial results Annual utility cost savings IRR Payback time
20 % 48 % 1.4 years
People vs. technology Share of savings from: - People involvement - Technical sub projects
30 % 70 %
Plant data Plant size Total production Segment Country
900 people ~5 mio units p.a. Manufacturing Slovenia
Implementation phase (8 months) Focus on people, systems, and technology
Background information Danfoss Compressors is one of the global leading manufacturers of compressors with low energy consumption. December 2008 Record month: EUR 64,500 savings - equal to 77% above target
Initial situation and challenges
May 2009 Savings reach more than project target of EUR 435,000 five months before project end
DanfossSo utions
Like many other companies Danfoss Compressors d.o.o is fighting the consequences of the financial crisis trying to reduce costs without lowering the level of R&D investments and maintaining the high quality level of the products. “The savings are particular important now during the economic crisis” says Jurij Derganc, Project Manager. Before the project started, there was only one electricity meter in the entire plant, which meant that none of the employees knew how much energy his or her machine was consuming. Electricity amounted to 66% of the plant's total energy bill - more than the total for oil, gas and water. The potential of savings resulting from getting an overview from additional meters and the subsequent remedial actions was thus interesting.
October 2009 Project end - total savings of EUR 585,000,- work on saving energy continues internally
Danfoss Compressors d.o.o in Slovenia is engaged in the production of household cooling compressors. The company both manufactures components and assembles these to finished products. The annual utility consumption before the EnSave® project amounts to approx. 3 mill Euro. The site typically produces seven days a week in three shifts.
▼
The household division of Danfoss Compressors started to save energy at three factories in 2008. They decided to begin a fight against CO2 emissions for the sake of the environment and to save money. Danfoss Solutions has been a partner in this process and supplied the project model EnSave®. Page 1 of 2
What does Danfoss in Slovenia say about the EnSave® project?
“It is amazing how much you can do relatively fast. Cutting energy use does not have to be rocket science.” Jurij Derganc Project Manager
“The savings are major. If you take the electricity meter, you can almost see it for yourself, just by looking at it.” Jurij Derganc Project Manager
What was done? The project has put focus on three main areas: People, Systems and Technology. Examples: People: • Appointing utility responsibles for single machines/processes • EnSave® Team formed with representatives from most departments • Comprehensive reporting workshops • Everybody is saving energy – even in the company tennis court Systems: • Implementing a significant number of new utility meters • Montage™ – utility management software – implemented • Utility consumption now part of management meetings • Performance indicators established Technology: • Air Compressors: Common control system, VLT® frequency conver- ters on one compressor, fresh air ducting on air inlet • Humbert oven: New control system, new burners, heat recovery • Light system: New fixtures, automatic control system • Steam system: Automated blow down system, general steam system revamp • VLT® frequency converters on cooling tower pumps and fans • Heat recovery on drying ovens
What are the results? EUR 470,000 - that is the amount the Danfoss Compressor factory in Slovenia managed to cut off its energy bill annually. From January 2008 to end of September 2009 savings reached EUR 585,000. CO2 emissions have been reduced with 5,200 tonnes annually. Most of the savings have been realized by cutting the factory’s electricity use through a series of relatively simple measures and many activities. These include a sensor solution in compressor room that switches machines to stand-by or switches off when they are not in use, a system for reusing warm air, and the replacement of more than 1,000 old-fashioned strip lights with fewer and more energy-friendly tubes.
Jurij Derganc Project Manager
Accumulated Savings in EnSave® Project
700 600
Actual savings EUR 585,000 (20%)
500 1.000 EUR
“Our goal was to cut our energy bill with 435,000 euro by the end of September 2009, so the result of 585,000 euro exceeds everyone’s expectations. And the savings are particularly important now during the economic crisis.”
SAVINGS
The achievement is also a result of a great cooperation at all levels. The organization has understood to challenge each other but also having fun doing it.
Guaranteed savings EUR 435,000
400 300 200 100 0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep 2008
2009
per 31-09-2009
Project spinoff Large savings were seen on maintenance cost and reduction of unplanned stops on the Humbert oven.
DanfossSo utions · Birkemose Allé 33 · DK-6000 Kolding · Tel. +45 7488 7100 · www.solutions.danfoss.com
Page 2 of 2
at Danfoss Compressors d.o.o. in Crnomelj, Slovenia FACTS
EnSave® Project Highlights May 2007 EnStudy® Analysis of energy consumption identification of potential savings
September 2007 Verification & Planning (3 months)
January 2008
EnSave® case in brief Environmental impact CO2 emissions reduction CO2 reduction “per employee”
5,200 tonnes p.a. 5.5 tonnes p.a.
Financial results Annual utility cost savings IRR Payback time
20 % 48 % 1.4 years
People vs. technology Share of savings from: - People involvement - Technical sub projects
30 % 70 %
Plant data Plant size Total production Segment Country
900 people ~5 mio units p.a. Manufacturing Slovenia
Implementation phase (8 months) Focus on people, systems, and technology
Background information Danfoss Compressors is one of the global leading manufacturers of compressors with low energy consumption. December 2008 Record month: EUR 64,500 savings - equal to 77% above target
Initial situation and challenges
May 2009 Savings reach more than project target of EUR 435,000 five months before project end
DanfossSo utions
Like many other companies Danfoss Compressors d.o.o is fighting the consequences of the financial crisis trying to reduce costs without lowering the level of R&D investments and maintaining the high quality level of the products. “The savings are particular important now during the economic crisis” says Jurij Derganc, Project Manager. Before the project started, there was only one electricity meter in the entire plant, which meant that none of the employees knew how much energy his or her machine was consuming. Electricity amounted to 66% of the plant's total energy bill - more than the total for oil, gas and water. The potential of savings resulting from getting an overview from additional meters and the subsequent remedial actions was thus interesting.
October 2009 Project end - total savings of EUR 585,000,- work on saving energy continues internally
Danfoss Compressors d.o.o in Slovenia is engaged in the production of household cooling compressors. The company both manufactures components and assembles these to finished products. The annual utility consumption before the EnSave® project amounts to approx. 3 mill Euro. The site typically produces seven days a week in three shifts.
▼
The household division of Danfoss Compressors started to save energy at three factories in 2008. They decided to begin a fight against CO2 emissions for the sake of the environment and to save money. Danfoss Solutions has been a partner in this process and supplied the project model EnSave®. Page 1 of 2
What does Danfoss in Slovenia say about the EnSave® project?
“It is amazing how much you can do relatively fast. Cutting energy use does not have to be rocket science.” Jurij Derganc Project Manager
“The savings are major. If you take the electricity meter, you can almost see it for yourself, just by looking at it.” Jurij Derganc Project Manager
What was done? The project has put focus on three main areas: People, Systems and Technology. Examples: People: • Appointing utility responsibles for single machines/processes • EnSave® Team formed with representatives from most departments • Comprehensive reporting workshops • Everybody is saving energy – even in the company tennis court Systems: • Implementing a significant number of new utility meters • Montage™ – utility management software – implemented • Utility consumption now part of management meetings • Performance indicators established Technology: • Air Compressors: Common control system, VLT® frequency conver- ters on one compressor, fresh air ducting on air inlet • Humbert oven: New control system, new burners, heat recovery • Light system: New fixtures, automatic control system • Steam system: Automated blow down system, general steam system revamp • VLT® frequency converters on cooling tower pumps and fans • Heat recovery on drying ovens
What are the results? EUR 470,000 - that is the amount the Danfoss Compressor factory in Slovenia managed to cut off its energy bill annually. From January 2008 to end of September 2009 savings reached EUR 585,000. CO2 emissions have been reduced with 5,200 tonnes annually. Most of the savings have been realized by cutting the factory’s electricity use through a series of relatively simple measures and many activities. These include a sensor solution in compressor room that switches machines to stand-by or switches off when they are not in use, a system for reusing warm air, and the replacement of more than 1,000 old-fashioned strip lights with fewer and more energy-friendly tubes.
Jurij Derganc Project Manager
Accumulated Savings in EnSave® Project
700 600
Actual savings EUR 585,000 (20%)
500 1.000 EUR
“Our goal was to cut our energy bill with 435,000 euro by the end of September 2009, so the result of 585,000 euro exceeds everyone’s expectations. And the savings are particularly important now during the economic crisis.”
SAVINGS
The achievement is also a result of a great cooperation at all levels. The organization has understood to challenge each other but also having fun doing it.
Guaranteed savings EUR 435,000
400 300 200 100 0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep 2008
2009
per 31-09-2009
Project spinoff Large savings were seen on maintenance cost and reduction of unplanned stops on the Humbert oven.
DanfossSo utions · Birkemose Allé 33 · DK-6000 Kolding · Tel. +45 7488 7100 · www.solutions.danfoss.com
Page 2 of 2
