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Improving Energy Efficiency at U.S. Plastics Manufacturing Plants: the case of Superfos Packaging

Last updated: Jan 17, 2025

Summary

In 2003 The Society of the Plastics Industry, Inc. (SPI), a major trade organization, began working with the U.S. Department of Energy (DOE) on a series of energy assessments at several SPI member companies’ plants, as part of DOE’s established Allied Partnership activities. The 11 companies included in this study represent a broad cross-section of the industry in terms of size, production processes, and variety of products. This is a focus on the case of Superfos Packaging.

Problem

Rising energy prices are becoming a major concern in the plastics industry. This is especially true for small- and medium-sized companies that have little wiggle room when trying to balance operating expenses against profi tability

Solution

West Virginia University’s Industrial Assessment Center (IAC) performed an energy audit at Superfos Packaging in Cumberland, Maryland. Superfos Corporation is one of the largest plastic packaging specialists in Europe and is expanding into the U.S. market. The Cumberland facility measures 187,000 square feet in size and operates continuously, 7 days per week. Energy costs at the plant total approximately $760,000 per year. During the assessment, the IAC team found that Superfos could save electrical energy by insulating heated surfaces on molding equipment, starting a motor management system program with the help of a software tool, improving the compressed air system, and making changes in the lighting system. These energy enhancements will reduce electrical energy consumption by 7,950 MMBtu per year.

Outcome

By putting into practice the IAC assessment recommendations, the Superfos Cumberland plant will lessen its annual electricity consumption by more than 2.3 million kWh, or 7,950 MMBtu. This translates to costs savings of nearly $100,000 per year (a 13% reduction on the $760000 annual energy cost). Furthermore, the company’s actions improve environmental performance, reducing carbon dioxide emissions by more than 5 million pounds per year. A big portion of total reduction in energy consumption and consequently in cost saving comes from insulating molding machines surfaces (5,464 MMBtu and $76,401). For a total investment of only $3911, the payback period of most interventions is just one month.