Aptar Villingen GmbH
Packaging specialist Aptar Villingen GmbH focuses on resource-conserving use of energy
With more than 14,000 employees in 20 countries, the packaging company Aptar manufactures containers, dosing solutions and dispensing systems for various industries – from cosmetics and personal care to medicines, food and beverages. Aptar is one of the largest manufacturers of dispensing systems in the world. The production of packaging is one of the most energy-intensive industries.
This is precisely why sustainability and the resource-saving use of energy have been high on Aptar's agenda for years. The company has brought its energy and greenhouse gas emission targets in line with the latest climate science and developed an ISO 14064-compliant energy management system. Aptar is ranked among the most sustainable companies in America by the American weekly magazines Barron's and Newsweek 2020.
The company is represented at seven locations in Germany. The energy management solution from econ solutions is in use at four sites: in Radolfzell, in Eigeltingen and at the two plants in Villingen.
With more than 30 years of experience in airless technology, the Villingen plant manufactures application systems for the cosmetics, personal care and pharmaceutical industries. Increased environmental awareness prompted the introduction of an environmental management system in accordance with ISO 14001 a few years ago. This was followed in 2013 by the introduction of an energy management system in accordance with ISO 50001, due to the company's various CSR initiatives, rising energy prices, stricter legal requirements and future competitiveness.
Manuell, intransparent, zeitaufwändig
Wie so oft erfolgte die Energiedatenerfassung zunächst denkbar einfach – nämlich manuell. Das war der Fall für das Ablesen aller Messstellen, das Eintragen der abgelesenen Werte in verschiedene Listen oder das Aufbereiten der Daten durch den Energielieferanten in bestimmten Intervallen. Zeitnahe Transparenz über den Energieverbrauch war so nicht möglich. Auffälligkeiten und Unregelmäßigkeiten konnten gar nicht oder nur begrenzt erst im Nachhinein erkannt und definiert werden. Die komplette Aufbereitung der manuell erfassten Daten in Reports war fehleranfällig, zeitaufwändig und kostenintensiv.
Daher war schnell klar, dass eine automatisierte Energiedaten-Erfassung und ein entsprechendes Energie-Monitoring vonnöten sind. Wichtig war, dass in diesem System alle unternehmensrelevanten Kennzahlen dargestellt werden können. Außerdem sollte eine lückenlose und permanente Aufzeichnung der relevanten Messdaten sichergestellt sein. Um auf Basis der Vorgaben durch das Erneuerbare Energie-Gesetz (EEG) und das Energie-Dienstleistungsgesetz (EDL-G) auch zukünftig vom Spitzenausgleich profitieren zu können, installierte Aptar in den beiden Werken in Villingen sowie in Radolfzell und Eigeltingen ab 2015 ein Energie-Monitoringsystem.
Auswahl der optimalen Softwarelösung
Neben den unternehmensrelevanten Kennzahlen und Reports für die ISO 50001 sollten diese auch für die ISO 14001 dargestellt werden können. Zusätzlich sollte das Messsystem auch die Netzqualität und deren elektromagnetische Verträglichkeit bzw. deren Auswirkungen überwachen, um die Ausfallsicherheit der Produktion zu gewährleisten. Denn durch immer mehr Leistungselektronik in der elektrischen Anlage hatten die auftretenden Belastungen zugenommen.
Aptar entschied sich aufgrund der bedienerfreundlichen Benutzeroberfläche sowie der zahlreichen individuell konfigurierbaren Auswertungs- und Berichtsmöglichkeiten bei der Energiemanagement-Software für econ solutions. Außerdem stattete econ solutions die vier Standorte von Aptar mit der nötigen Hardware aus, darunter die Datenlogger econ unit+. Bei der Messtechnik kam die Firma Janitza zum Zug. Der Technologiedienstleister Alexander Bürkle war für die Planung und Implementierung des Gesamtprojekts in Villingen verantwortlich.
Initial successes already during commissioning
As of January 2021, the system consists of around 50 measuring points that are connected online via Ethernet or Modbus, plus 170 additional virtual measuring points. Electricity and other media are measured. The first findings were already available when the system was commissioned: Shortly after its introduction, the first financial success was a 50 kW reduction in peak loads and a 20 kW reduction in the base load at weekends. In addition, the compressed air network was lowered by 2 bar without affecting usage. These measures enabled the company to save 20,000 euros per year in energy costs.
"Thanks to the energy management solution from econ solutions, we can access a completely different quality of data at a completely new level of resolution – at the touch of a button. This enables us to uncover, evaluate and rectify energy consumption and load curves that are not visible from the outside"
Daniel Ross, EHS Manager at Aptar GmbH Villingen
The most noticeable deviation in energy monitoring came from a commercially available compressor control system. This measures the current and determines the amount of compressed air produced via the compressor characteristic curve. With the help of compressed air measurement technology, a deviation of more than 20 percent of the calculated output of the compressor control system was detected. Based on this finding, Aptar purchased an ultrasonic leak detector to detect compressed air leaks. This investment had already paid for itself with the first leak found: Six more compressed air leaks were found. In total, the leaks had caused an energy loss worth 18,000 euros.
"The automated and always up-to-date display of key figures at the touch of a button was crucial for the internal acceptance of energy management. At the same time, the implementation of the system was the start of improved communication around the topic of energy management in the company," adds Daniel Ross.
The more than 7,000 square meter extension for production and administration in Villingen, with which the Villingen and Pfaffenweiler sites are to be consolidated, will also be successively equipped with measuring points from econ solutions. "We expect this to lead to a significant improvement in energy efficiency in the areas of heating, lighting and buildings. The consolidation will improve our CO2 consumption. This can only be proven in conjunction with the solution from econ solutions," says Daniel Ross, explaining the future plans.