- 11% of all UK carbon emissions are resultant of the manufacturing industry.
- 60% of manufacturers have seen a 20% increase in their energy bills in the past 12 months.
- 90% of manufacturers are aware of net zero carbon by 2050 target
As the manufacturing industry looks to rebuild and grow post lockdown, there is an opportunity for manufacturers to look at their sustainability goals and work with Government to deliver a green recovery.
Research, undertaken in partnership with leading energy company E.ON prior to the lockdown indicates that sustainability and profitability go hand in hand:
Manufacturers who put sustainability at the heart of their businesses have seen real benefits from doing so in the last 12 months with 40% reporting increased profit margins and 30% increased competitiveness as a result.
In most sectors of manufacturing, large volumes of electricity is needed. Many processes require the heating up and cooling down of raw materials and so much hot and chilled water is required. Electricity is often from the grid, hot water is supplied by fossil fuel hot water or steam boilers and chilled water supplied by conventional HFC water chillers, or for sub temperature cooling ammonia chillers.
What if your hot water heating costs and resultant carbon could be eliminated?
What if your cooling costs and carbon could be cut in half?
What if by generating your own electricity on site you could cut your electric costs by 20-40%?
Manzana work with manufacturers to reduce energy costs and carbon. We offer a free off charge site audit to identify quick pay back energy efficiency measures.
All solutions can be financed, meaning zero upfront investment. We target solutions with 2-3 payback, that can be financed over 4-6 years, making it profitable from year 1.
For manufacturers who are more serious about energy reduction, we can help you develop a full energy transition strategy. Working with our partners we can provide a number of funding options for energy transition projects:
Energy savings agreements – 0% investment or repayment. Running cost savings shared between you and funder
Hire Purchase agreement – 0% upfront investment, repayments circa 50% of savings. Equipment is your asset from day 1 attracting enhanced capital allowances.
Lease Purchase agreement – VAT paid upfront (20%), repayments circa 60% of savings. Off balance sheet option.
You can of course purchase our solutions without finance. After the 2 -3 year payback period, all savings are then yours!
We have many solutions to reduce energy use and running costs in manufacturing facilities, here are some of our favourites:
Does this sound like the sort of future you wish for your children’s, children?
Free Cooling Generated From Waste Hot Water
Do you have waste hot water from your manufacturing process?
Did you know you can use it to drive a chiller which produces chilled water? What if you could use this hot water to run the system instead of expensive mains electricity?
An absorption chiller, is a chiller that uses a heat source to provide the energy needed to drive the cooling process. The system uses two coolants, the first of which performs evaporative cooling and is then absorbed into the second coolant; heat is needed to reset the two coolants to their initial states. This technology was commonly used in refrigerators 60 years ago but was phased out as electrically driven units, were both cheaper to manufacture, cheaper to run and cheaper to purchase. The technology uses dramatically less electricity than that, used by a usual refrigerator, with the main driving energy being heat. In the old fridges, gas would be directly fired to provide this heat. The total energy used to do this was greater than that used running an all electric, vapour compression cycle refrigerator and so this technology took over. Absorption technology is making a come-back in manufacturing and industry, however. If you have waste heat from processes, this means that the heat energy is not directly paid for, meaning that the only paid for energy input is a small amount of electricity to run the turbine and other electronics. Effectively you put hot water in one end and chilled water will come out the other with end, with very little cost and carbon resultant of this.
Free Hot Water From Chiller Plant
Do you have a requirement for both chilled and hot water for domestic hot water/comfort cooling or/and for manufacturing process purposes? What if we could completely eradicate your heating cost? How much would you save?
Our dual energy heat pumps produce hot and chilled water simultaneously. In refrigeration, the by product of cooling is heat. In most manufacturing facilities, the heat from the cooling process is dissipated to outside atmosphere using fans on the condenser or via a dry air cooler. Dual energy heat pumps use C02 or R513a (HFO) refrigerant. The C02 variant is perfect for applications where you need large volumes of hot water up to 90 degrees and also have a cooling load. The dual fuel heat pump is installed on the return to the exiting chiller plant. By doing so, it acts as the lead chiller and while there is cooling load, produces free hot water for use in process or for domestic hot water purposes.
Free Electricity Generated FromUnwanted Process Hot Water
Do you have waste heat from your manufacturing process? Did you know you can use it to generate cheap low carbon electricity allowing quick pay backs?
Organic Rankine Cycle (ORC) technology is used to generate low cost electricity ORC units can produce electricity all year long, 24/7 and is clean and stable power. In simple terms, ORC units use hot water to drive a turbine, which in turn generates electricity.In many manufacturing facilities, heat is thrown away using in cooling equipment. This heat can be harnessed via heat exchangers and fed to the ORC unit, generating electricity from what would have been wasted energy.
Until recently, the manufacturers in this industry only provided large scale systems, for big energy producers. Recently, smaller units have been released to the market so that manufacturers can use waste heat to produce their own, low carbon, low cost electricity.
Generate Cooling During Off-Peak Times, Store & Use It When You need it
Cold Batteries are a product which can be used to store cooling energy. Cold batteries are made from various materials which are highly efficient in storing cooling. Storing cooling in cold batteries in comparison to storing in water, reduces volume by 2/3’s and so large amounts of energy can be stored in a relatively small space.
Why store cooling?
- Chillers can be run at time that cheap (off-peak) electricity is available
- Additional cooling can be stored for peak cooling requirements if plant is not big enough
- By product cooling energy can be stored for when it is needed
- Night-time noise restrictions can prohibit chillers being run, storage makes cooling available at these times
Low Carbon, Low cost electricity
Do you use lots of electricity on site?
Do you also have a constant demand for either chilled or hot water? What if you could produce low cost electricity onsite and as a bi-product produce chilled or hot water?
Combined Heat and Power (CHP) converts gas into both electricity and heat. CHPmaximises the fuel and converts it intoelectricity at around 35% efficiency andheat at around 50%. Heat is recovered fromthe engine by removal from the exhaust,water jacket and oil cooling circuits.
Typically a good CHP scheme can deliver anefficiency increase of anything up to 25%compared to the separate energy systemsit replaces.
The heat produced by the CHP engine, is often used for space heating or domestic hot water purposes. To make CHP work all, or the majority of the heat needs to be used. This is because the carbon free nature of the hot water produced by the CHP offsets the relatively high carbon content of the gas which is used to run the engine generator.
If there is insufficient heating load, the next consideration should be the cooling load on the site. The heat produced by the CHP engine can also be used to drive an absorption chiller (please see cooling section of this website), allowing the bi-product heat to be fully utilised to satisfy the site cooling demand.
We care about the environment
At Manzana, we care about the world we live in. We know how much difference the implementation of a building service energy strategy, can have on energy use and carbon emissions. We feel it is our responsibility to guide businesses like yours to achieve considerable energy reduction
15 years experience of low carbon technology
We have more than 20 years experience in mechanical and electrical Engineering. More than 15 years of this has been working with low carbon and renewable technology. We have had first-hand experience of thePro’s and con’s of various technologies through their life time. We have learnt what is required to provide solutions that deliver as intended.
We tailor solutions to your business
Achieving energy, carbon emissions and running cost savings in commercial and industrial settings is far from a one size fits all situation. It is important to understand exactly how much cooling, heating and electricity you use, where and when waste heat/cooling is available and at what times during the day. As part of our free consultation we identify this and then design a scheme Which takes all of this into account.