GreenEcoNet

Connecting SMEs for a green economy

Resource-efficient waste disposal in a packaging business

Andreas Bauer's picture

In each EffCheck, used resources are considered across environmental media and in a process-oriented way, in order to reveal efficiency potentials in material and energy use and to reduce the emergence of waste and wastewater.

The small business
Chemotechnische Abpack-Service GmbH (CAS) started small, with just two employees. Over three decades later, CAS – now with 35 employees – has established itself as a reliable and performing business for the packaging of soft and solid pastes and liquid products.
Since 2000, the plant is equipped with 6 waste compactors of 35-100 bar. In the 2,500 m2 plant, tubes, cartridges, bottles, cans and foil bags are filled with silicone, polyurethane, polysulfides, acrylic glues, epoxy resins, butylene, pigment pastes, lubricants, and many other substances. Customers are mainly from the automobile sector, the building sector, the aviation industry, and the glass, and wood, metal and printing industries. Since 2004, CAS is a member of the association for sealants. In 2006; CAS received ISO 9001 certification for its quality management.
“EffCheck was just the right instrument for us!”- Hans-Jürgen Reusch, CEO

Potentials identified through EffCheck
(1) Measure (2) Investment in € (3) Cost savings in €/year (4) Amortisation

(1) New waste management concept (recovery of redisual materials) (2) 0 (3) 36,500 (4)immediate

(1)New prenumatic compressor (2) 5,000 (3) 1,500 (4) 3-4 years

(1) Optimization of the lighting system (2) 4,400 (3) 1,300 (4) 3-4 years

(1) Installation of efficient engines (2) 2,000 (3) 800 (4) 2-5 years

EffCheck Results
• Example 1: Installation of efficient engines
Several motors had a bad efficiency (cos-phi-value). They were replaced with motors with a good efficiency. This involved 9 out of 15 motors, because they almost continuously run during production. This measure not only reduces energy use by more than 2,500KWh/year, but the idle power also decreases significantly. With a one-time investment of 2000€ (without financing), the small business saves more than 800€ and circa 1.6 tonnes of CO2 per year.

• Example 2: New waste management concept.
Previously, employees did not check whether it was possible to generate additional revenue when disposing of waste. Waste was left to the disposal firm, sometimes for free and sometimes at a cost. According to market surveys, additional revenues of up to 36.000€ could be generated.

• Example 3: Compressed air
The current pneumatic compressor is too big, runs with too high pressure and is idle 50% of the time. The additional pressure consumes 4,440KWh per year and the unnecessary idle time consumes 5,840kWh per year.
Together, this represents about 49% of total consumption, which can be spared through the installation of a better suited pneumatic compressor. The CO2 savings would be 6.4 tones per year.

EffCheck – Consistently comprehensive
In each EffCheck, used resources are considered across environmental media and in a process-oriented way, in order to reveal efficiency potentials in material and energy use and to reduce the emergence of waste and wastewater.

Project theme:
A packaging business greens their operations through an efficiency check by EffCheck.

Project implementation:
Chemotechnische Abpack-Service GmbH
Im Brückgraben 1
65558 Kaltenholzhausen
www.abfuellservice-cas.de

Contact:
PIUS-Internet-Portal
c/o Effizienz-Agentur NRW
Henning H. Sittel
Tel. 0203 378 79 51
E-Mail: info@pius-info.de

Green Eco Net
c/o Ecologic-Institut gGmbH
Dr. Martin Hirschnitz-Garbers
Tel. 030 86880 272
E-Mail: martin.hirschnitz-garbers@ecologic.eu

Source in german: EffNet http://www.pius-info.de/dokumente/download/1773/

Further details

Would you characterize the green solution as: 
Medium capital intensive investment (i.e. €10,000-€30,000)