Transcript Energy Efficiency through Product & Process Design

This project has been assisted by
the New South Wales Government
through its Energy Efficiency Training Program
Energy Efficiency
through Product & Process
Design
Prepared by
Prepared by Plastics Industry Manufacturers of Australia (PIMA)
in partnership with Australian Management Academy (AMA);
executed in collaboration with EcoProducts
Copyright and disclaimer
The Office of Environment and Heritage and the State of NSW are pleased to allow this material to be
used, reproduced and adapted, provided the meaning is unchanged and its source, publisher and
authorship are acknowledged.
The Office of Environment and Heritage has made all reasonable effort to ensure that the contents of
this document are factual and free of error. However, the State of NSW and the Office of Environment
and Heritage shall not be liable for any damage which may occur in relation to any person taking
action or not on the basis of this document.
Office of Environment and Heritage, Department of Premier and Cabinet
Phone: (02) 9995 5000 (switchboard)
Email: [email protected]
Website: www.environment.nsw.gov.au
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Energy Efficiency
through Product & Process
Design
Module 9 – Energy Efficient
Manufacturing through Product Design
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Products Agency
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Key Points
Energy-efficient product design across the life cycle
1.
2.
3.
4.
5.
6.
Polymer manufacturing
Primary processing
Secondary processing
Distribution
Use phase
End-of-Life
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Product Life Cycle
Recycling
Feedstocks
Primary
Processing
Secondary
Processing
DIstribution
Use
Disposal
Polymer
Manufacturing
Landfill
Production Phase
Use Phase
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End-ofLife
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Light-Weighting
• Light-weighting has many benefits across the
lifecycle and should be a priority
• Optimum design can take out weight without
compromising function
–
–
–
–
Analysis
Prototyping
Testing
Optimizing
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Light-Weighting
OLD
NEW
VW Golf
bumper
2005
2009
Weight
reduction
3.212 kg
2.999 kg
6.6%
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Light-Weighting
2006
2009
Weight
reduction
BMW 7 series
dash
7.436 kg
4.616 kg
38%
BMW 7 series
accelerator
pedal
0.518 kg
0.330 kg
36%
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Light-Weighting
45
40
35
30
25
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10
5
0
energy per bottle (Wh)
35
30
Wh/bottle
grams per bottle
weight (g)
25
20
15
10
5
0
Trends in Coca Cola 500 mL PET bottle weights
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Light-Weighting
Achieved by:
• Optimising Base design
• Optimising neck and closure design
• High precision and process consistency
• Improved PET grades
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Recycle Content
• Recycling recovers the embodied energy – new
(virgin) plastic doesn’t have to be made
• Energy required for reprocessing is much less
than embodied energy
Embodied Energy (MJ/kg)
25
20
15
10
5
0
virgin PP
30% recycle
PP
50% recycle 100% recycled
PP
PP
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Recycle Content
• Recycled content can also be a marketing
advantage
• Becoming widely accepted or mandatory
UK juice bottle with On-Pack labeling
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Biopolymers &
Biocomposites
• Bioplastics made from renewable feedstocks
have lower embodied energy
PLA bioplastic compared to conventional plastics
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Product Life Cycle
Recycling
Feedstocks
Polymer
Primary
Manufacturing Processing
Secondary
Processing
DIstribution
Use
Disposal
Landfill
Production Phase
Use Phase
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Products Agency
End-ofLife
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Material Selection
• Plastics require different amounts of energy to
heat to the process temperature
Polymer
PVC
Energy to heat from
20o to 150oC (kWh/kg)
0.05
LDPE
0.15
• But in practice this is not significant as only 510% of the input energy goes into the polymer
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Material Selection
• Low density materials use less processing
energy per unit volume
• High flow, low melting point saves energy
• Higher performance materials can allow thinner
walls and lighter weight
• Lubricant additives in extrusion processes
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Material Selection
Eliminate or minimize energy use for drying
Need drying
May not need drying
Polyamide (Nylon)
Polypropylene
Acrylic
Polyethylene
Polycarbonate
PVC
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Process Selection
•
•
•
•
Extrusion processes generally have lower SEC
Minimize the number of parts by integration
Multi-cavity tools
Hot-runner tools
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Light-weighting
• Reducing the amount of material saves energy
in primary processes
–
–
–
–
Less material to dry
Less material to heat
Lower requirement for cooling
Faster cycle times
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Light-weighting
• Foaming
– Chemical blowing agents
– MuCell®
• Hollow part technologies
– Gas injection
– Water injection
– Projectile injection
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Example
BMW Fan Shroud
–
–
–
–
MuCell™ supercritical gas foaming process
Glass fibre polyamide material
8% weight reduction, 22% cycle time reduction
30% injection machine clamp force
reduction allowed hinge to be
moulded in the same tool
– energy saving 30% +
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Trimming
• Trimming operations use energy
– Blow moulding flash removal with saws, punching jigs
– Drilling, routing
• Additional energy used for granulating off-cuts
• Design to eliminate or minimise trimming where
possible
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Joining & Assembly
• Welding operations use energy
• Consider alternatives during design
– Snap-lock assembly
– Adhesive joining
– Part integration
• Minimise part movements
– Assembly at the primary process
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Painting & Decorating
• Integrate with primary process
– In Mould Decoration and Labelling
• Avoid paint drying ovens
– Powder coat processes
– UV curing
• Eliminate painting
– through-coloured materials
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Example
Peugeot 206+ Radiator Grille
– Achieves metallic look without painting
– Borealis Daplen™ EH104E-0515 polypropylene
compound
– High-flow (MFI 40) minimizes number of injection
points and weld lines
– special metallic pigment system
provides equivalent appearance
to paint
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Product Life Cycle
Recycling
Feedstocks
Primary
Processing
Secondary
Processing
DIstribution
Use
Disposal
Polymer
Manufacturing
Landfill
Production Phase
Use Phase
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End-ofLife
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Reduce Packaging
• Unit packs, store packs, warehouse packs
– Delete a level
• Eliminate unnecessary over-packaging
EnvironmentVictoria 2008 ‘Golden DUMP
(Damaging & Useless Materials in Packaging)’
Award winner for 2008
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Packing Density
• Kraft 300 mL PET liquid dressing bottle
• Redesign achieved 13% weight reduction and
21% increase in pallet utilization
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Returnable Packs
• Returnable 23 litre produce tray (Viscount)
• Replaces corrugated cardboard tray with a
lifetime of 1 – 5 trips
• Achieves several hundred trips with less
damage to stock
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Energy in Use
Well designed products may result in
greater energy efficiency when in use
Product
Energy saving
Light weight vehicle
components
Reduced vehicle weight and improve fuel
efficiency
Plastic wine bottles
Increased aircraft payload
Light weight crates
increased truck fuel efficiency during
distribution
Collapsible crates
Higher stacking density, fewer truck
movements
Thermal insulation
Reducing heat loss
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Product Life Cycle
Recycling
Feedstocks
Polymer
Manufacturing
Primary
Processing
Secondary
Processing
DIstribution
Use
Disposal
Landfill
Production Phase
Use Phase
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Products Agency
End-ofLife
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End-of-Life Options
Repair and Re-use
Closed Loop Recycling
Down Cycling
Increasing life cycle
energy efficiency
Recovery (Energy
or Compost)
Increasing life cycle
energy use
Landfill
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Recovery & Recycling
• Recycling minimises energy life cycle energy
use compared to landfill or energy recovery
Life Cycle energy use for 1 kg of PET bottles
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Summary
• There are energy saving opportunities
throughout the life cycle
• Energy efficient design uses life cycle thinking
• Light-weighting has many energy saving
benefits
• Recycling can save energy through the life
cycle
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Products Agency
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