Borg Manufacturing modernise plant through energy savings

The Client
Borg Manufacturing is a leading Australian manufacturer of melamine panels, medium density fibre board (MDF), mouldings, doors, shelving and joinery components.

The Work
Borg Manufacturing appointed The Wattly Group for an energy optimisation project to provide upfront consulting, measurement and verification, and certificate creation services. The business was planning to upgrade one of its main dryer fans and needed the support of The Wattly Group to provide expertise around measurement, verification and certificates. The work done by The Wattly Group provided a baseline of data and plan to support the installation of a variable speed drive (VSD) to optimise the fans energy performance.

Key Facts

Equipment Upgraded Main dryer fan
Annual Energy Savings $150k
Project Payback Period $300k
Program 12 months
Certificate Energy Savings Certificate (ESC)

Challenges

  • Need for measurement and verification expertise
  • Limited understanding of the NSW energy savings certificate process for industrial projects
  • Insufficient knowledge on the method of applying for certificates
  • Need to develop a business case justifying capital expenditure required to modernising plant

Outcomes

  • Certificates paid for the dryer fan upgrade and installation of a variable speed drive (VSD)
  • Reduction in ongoing energy costs
  • Saving of over 15,000 tonnes CO2e over 10 years

DON Smallgoods large energy payoff

The Client
Founded in 1947, DON is one of Australia’s largest smallgoods manufacturers, producing ham, bacon, salami and smallgoods from its Castlemaine site in Victoria.

The Work
In 2017, DON Smallgoods engaged The Wattly Group for a three year contract under our ‘Virtual Energy Manager’ service to help set up an energy reduction program. The Wattly Group was selected as an energy optimisation partner based on their deep experience in industrial efficiency, articulation of value, ‘skin in the game’ approach and ability to measure success.

Challenges

  • No visibility of energy productivity and performance
  • Rapidly rising electricity costs
  • Need to achieve sustainability targets
  • Limited energy management knowledge
  • Unstructured approach to energy management

Outcomes

  • Greater visibility on energy performance
  • $1.5M of savings opportunities/ pipeline identified from energy assessment including upgrades to air compressors, refrigeration, lighting and process improvement
  • Reduced risk as a consequence of cofunding model
  • Project payback less than three years
  • Target annual energy savings of 20% of site energy use

Kimberly Clark Cleans Up With Energy Savings

The air handling transportation system was inflexible and inefficient until we upgraded it with variable speed drives and controls. With the help of Wattly we were able to verify the savings, and claim energy saving certificates that helped to offset the cost of the new system
Kimberly-Clark — Ingleburn Site Manager

The Client
Kimberly-Clark, manufacturers health, hygiene, and well-being products globally for over 175 countries. Brands include Huggies, U by Kotex, VIVA, Kleenex, Kleenex Cottonelle, Depend, Poise, DryNites, and Pull-Ups and many others.

The Work
Based on years of industrial energy experience, The Wattly Group was engaged to provide Kimberly-Clark with an end-toend energy optimisation solution. The scope of the project was to ensure their energy saving project complied with NSW energy savings scheme requirements and Kimberly- Clark could maximise the financial incentives.

Key Facts

Equipment Upgraded 29 large industrial fans and controls
Annual Energy Savings 680+ MWh
Certificate Value > $ 105,000
Program NSW Energy Saving Scheme (ESC)
Method Project Impact Assessment with M&V (PIAM&V)
Wattly Partner Northmore Gordon (Consulting)

Challenges

  • Rapidly rising electricity costs
  • Financial return on investment in energy efficiency upgrades
  • Complexity of accessing the financial incentives of the NSW Energy Saving Scheme (ESS)

Outcomes

  • Replaced manual control of air flow dampers with variable speed drives (VSDs)
  • Reduction in ongoing energy costs across the site
  • Saving of more than 7,000 tonnes CO2e
  • over 10 years
  • Met the payback criteria for site upgrade projects
  • Better control of the production process

Get in touch

1300 854 561

Australia

Melbourne

132 Cremorne St, Cremorne, VIC 3121

Newcastle

Level 1, 152/160 Hunter St
PO Box 1085, Newcastle, NSW 2300

Sydney

Level 3, 1-9 Buckingham St
Surry Hills, NSW, 2010

Singapore

20 Collyer Quay, #09-01
Singapore 049319

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