23/08/2023
How replacing a key machine at Norgren’s Brno factory cut energy use by 74%
Discover how optimising and updating a machine at Norgren’s Brno factory brought it one step closer to its sustainability goals.
The inspiration
Use the latest, most efficient equipment to improve sustainability in Norgren factories.
Could one piece of machinery really help Norgren reach its sustainability goals?
Norgren is aiming to reduce its carbon footprint by 50% by 2025. With such an ambitious target, the company can’t afford to take small steps.
Sustainability needs to shape everything. The planning of every process, the flicking of every switch, and the running of every machine.
That’s why optimising and updating machinery is an essential part of the carbon reduction journey. It’s the perfect way to discover inefficiencies that would otherwise have gone unnoticed – and make changes that reduce costs, as well as Norgren’s carbon footprint.
One of the most notable discoveries was the power of replacing a single piece of equipment at a Norgren factory in Brno, Czech Republic.
Tracking down production inefficiencies
Before the team could start making improvements, they needed to understand where to focus their attention. Assess the machines with the highest energy consumption, and decide whether they should be upgraded or replaced entirely.
The project soon identified one machine in particular that stood out from the rest: the machine that provides cool water for injection moulding machines.
Injection moulding is a key process at the Brno factory. There are 16 injection moulding machines on site – all of which require cooling many times in the course of a day.
Small inefficiencies in this process were adding up fast. Altogether, the out-of-date machine was wasting a significant amount of energy every day.
Fixing the problem was a challenge. But it was also a real opportunity: If Brno could find a greener, more efficient solution, it would have a noticeable effect on its carbon footprint.
Finding the perfect equipment
Once the team began digging into the performance of the machine, it was clear that a simple upgrade wouldn’t do. An entirely new machine was needed, one built using the latest technology and with sustainability in mind.
Extensive research led the team at Brno to find the best supplier on the market – one that understood their sustainability ambitions, and could provide the efficiency they were looking for.
The installation moved fast – and brought another opportunity to the forefront. While the new machine was being installed, several improvements were made to make maintenance of the equipment safer and easier.
Since the new machine is located on the roof of the compressor station outside of the factory, a footbridge with a railing was installed to make it simpler for people to reach the cooler and reduce the risk of a fall.
This made using and maintaining the machine significantly safer. As an added benefit, it will also make it easier to conduct maintenance more regularly, which in turn helps ensure the machine runs better for longer.
Greener. Bigger. Better.
The new machine delivered results immediately.
A larger cooling capacity. Lower energy consumption. And a more ecological type of refrigerant, which produces significantly fewer emissions.
Within eight months of installing the machine, Brno’s energy consumption had already significantly decreased.
Compared to running the same operation on the old cooling machine, energy consumption had been reduced by 74%. That’s around 45MWh.
Over the course of a year, average savings of around 74MWh are expected. This is equal to the annual average consumption of almost 25 Czech households.
In the process, the project has created a safer environment for Norgren employees. Helping to make Brno a safer place to work – while also looking after employees’ futures by doing everything possible to minimise Norgren’s impact on the natural world.
This is only the beginning for Brno and Norgren factories worldwide. The company is constantly assessing the machinery on its factory floors to find the most efficient, sustainable solutions. Continually exploring new technologies and new methods to make sure every process and piece of equipment is optimised and up to date.
There’s a theme that emerges time and time again on the journey to Norgren’s carbon reduction goals: Sustainability and efficiency go hand in hand. Changes that reduce the company’s carbon footprint don’t slow it down or overcomplicate its processes. They smooth out inefficiencies, uncovering time and cost efficiencies just as much as they cut down on emissions.
That’s why Norgren isn’t afraid to set ambitious targets. Because, when it comes to sustainability, this hard work always has a significant impact.
For more information about how Norgren is reducing its carbon footprint – and unlocking new benefits for its customers and people in the process – click here.