Intertape Successes in Energy Efficiency

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Intertape Successes in Energy Efficiency

• Presented By
• Michael B. Jones
• Manager of Engineering
• Intertape Polymer Corporation
• Danville, Virginia
• mbjones_at_itape.com

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Introduction

• Intertape Polymer Corporation (ITP)
• Founded in 1984
• Products
• Carton Sealing Tape
• Masking
• Specialty
• Duct Tape
• Stretch Film
• 10 Manufacturing Plants
• 2,500 Employees
• Sales - 737.2 million
• Competitors (3M, Shurtape, Tyco)

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Danville Facility Background

• Startup in 1989
• Products
• Hot Melt and Acrylic CST
• Stretch Film
• Duct Film
• 275 employees
• 500,000 SF, 13 expansions

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Danville Facility Energy Statistics

• 10,000 KW
• 60,000,000 KWH annually
• City of Danvilles largest electric customer
• 87,000 DT of natural gas annually

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Major Energy Consuming Equipment

• Electrical
• Extruders
• Infra-red Heaters
• Chillers (90 to 270 tons)
• Air Compressors 8 EA. _at_325 HP
• Natural Gas
• 7 Hot Oil Units (2.7 to 3.6 MMBTU/hr)
• 1 Steam Boiler (8.2 MMBTU/hr)

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Local Energy Management Team

• Form Team (Diverse Backgrounds)
• Brainstorm
• Prioritize
• Implement
• Measure Results

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2004 NCSU IAC Energy Audit
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2005 NCSU IAC Energy Audit
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Significant Implementations

• Cultural
• Gas
• Electric

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Culture

• Move coffee maker
• Implemented Turn off/Turn down Program
• Employee Energy Idea Contest (Paid Employee
  Electric Bill for top 3 ideas)
• Post Bills on Employee Monitors
• Boiler Training NC State, VPMEP, City of
  Danville
• Attended Green Seminar at Old Dominion U.
• Local Energy Management Team
• Read gas and electric meters every day
• Corporate Energy Management Team

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Corporate Energy Management Team

• Monthly Teleconference
• Report energy usage and costs
• Discuss projects (Share Ideas)
• Intercompany Energy Audits
• Subteam Meetings
• Corporate Steering Committee Report
• Annual Energy Summit

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Corporate Energy Summit

• Set Goal (4 reduction)
• Discuss Financial Status
• Discuss Plant Energy Projects
• Sub-team Discussions
• Guest Speakers
• Team Building Activities

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Gas

• Improved Combustion Efficiencies of Hot Oil
  Heaters
• Improve Efficiency of Steam Boiler
• Installing High Efficiency Hot Oil Heater
• Insulation improvements
• Acrylic Oven Improvements
• Steam Trap Audit
• Installed fixed thermostats on gas heaters
• Gas Purchasing strategies

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Electric

• Installed T5 Lighting in Warehouses
• Installed Insulation on Extruder Feed Throats and
  Dies
• Eliminated Acrylic chiller
• HM Coater Voltage Sag Protection
• Insulate Cast 7 Duct Line Feed pipes
• Economic Development Rider
• Install Programmable T-stats
• Purchase energy efficient motors
• Compressed air survey
• Reduced Air Pressure by installing Demand
  Expander
• Fiber Optic Meters
• Six Sigma Project

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Danville Accomplishments

• Savings since 2007
• Danville Facility - 420,000
• IPG Facilities 920,000
• 2008 E2 Energy Efficiency Award
• Case Study by NC State

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Future IPG Initiatives

• Process and Formulation Improvements
• 2009 Corporate Energy Summit
• Cogeneration
• Alternative Energy
• ISO 50001 Certification

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Implementing Energy Management

• Step 1 Gain Top Management Support
• Step 2 NCSU (IAC) Energy Audit
• Step 3 Form Local Energy Management Team
• Step 4 Implement Cost Savings Initiatives
• Step 5 Measure Results
• Step 6 Form Corporate Energy Team
• Step 7 Conduct Annual Corporate Energy Summit

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Conclusion

• Questions?