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Keeping an eye on energy usage can keep packaging companies sustainable

The packaging sector produces widely diverse types of end products, including aluminum cans, plastic bottles, corrugated board, polymer pouches, paperboard cartons, and more.

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One common denominator  uniting these disparate package types is the fact that energy consumption related to the manufacturing process and the costs associated with that consumption represent increasingly significant operational considerations. What’s more, energy consumption directly contributes to greenhouse gas emissions, impacting an organization’s carbon footprint.

In response to climate change pressure, leading retailers and consumer packaged goods companies are placing more emphasis on their supply chain to manage carbon. Wal-Mart, Procter & Gamble, Unilever, and many other companies have established formal plans to query their respective supply chain partners on energy consumption and associated carbon emissions and, in some instances, use those results as a metric for purchasing decisions. So to stay competitive, packaging organizations are wise to more deeply analyze their energy usage, develop a sustainability strategy, and implement optimization activities.

In general, packaging operations personnel can focus on three areas to help them do this: energy efficiency or reduction, renewable energy procurement, and carbon management.

Energy efficiency or reduction

Obviously, a reduction in energy consumption will reduce energy costs, but how can this be done in a packaging operation? Depending on the type of packaging operations, a number of opportunities exist to reduce energy consumption and, therefore, carbon emissions. A cultural shift within the organization—making each employee accountable for saving energy—can lead to substantial reductions.

To support an energy efficient culture, numerous energy efficiency projects can also be implemented to drive reductions. For example, analyzing compressed air and air handling systems and subsequently optimizing the energy usage by compressors and related piping systems is one way to have an impact on overall energy usage. Lighting retrofitting is another. The use of light sensors and new energy-efficient lighting technologies and bulbs can be introduced into plant environments to minimize wasted electricity. Shutdown optimization, demand control, and HVAC optimization are other key methods for reducing energy usage and boosting efficiency. Installing variable frequency drives and more efficient and optimally sized electric motors can significantly lower energy consumption.

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