Benchmarks & Client Cases
Efficiency in Polymer Production
The Challenge
Production generated waste
Water leakage
Problem
• Lack of awareness of energy and sub-product waste
• A lot of waste generated by production department
• Recurrent equipment stops due to breakdowns, causing peak energy consumption and scrap
• Variable chemical consumption between references
Root Causes
• Unknown causes of main energy losses
• Each breakdown is treated as an individual event with no use of previous event data
• Product formula prepared based on operator experience and perception
The Solution
Visual representation of critical equipment losses
• Visual representation of critical equipment losses
• Creation of a control chart with real-time data for process monitoring
• Improvement to processability of generated waste through equipment adaptation
• Redesign of energy circuits to eliminate redundancy
• Reengineering of product formulas to guarantee as little waste generated as possible and efficient use of raw materials
The Results
The project generated Annual Savings of $2.48 million.
Energy consumption
Energy consumption reduced by 6%.
Waste production
Waste production reduced by 14%.
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