- We have implemented Energy Awareness Training programme
- Thanks to energy awareness programmes we remain on track to meet our 2020 objectives and have reduced energy use per cubic metre of product by 17.5% since our 2010 baseline.
- We have made significant machinery and technology upgrades in a number of our biggest plants.
Knauf Insulation energy awards
Our energy awards recognise those plants that have demonstrated outstanding performance during the year. The awards are also designed to share good practice and provide all our energy managers with fresh ideas and inspiration. Last year the winners of Knauf Insulation’s 2015 Energy Awards presented during the meeting include Femi Olatunji from Cwmbran for Best New Starter Energy Manager, Laurie Vanicatte from Artix for Best Performing Energy Manager, as well as plant awards given to our Eskişehir plant (Turkey) for Most Improved Plant and Nova Bana plant (Slovakia) for Best Plant overall.
QHSE MANAGEMENT SYSTEM
Knauf Insulation follows the important International Management Standards. We are certified by one of the leading conformity assessment organisations, Bureau Veritas.
Knauf Insulation’s management system is based on the continual improvement framework outlined in:
- OHSAS18001 (Health and Safety Management) for all our Europe, US, Russia and CIS Plants.
- ISO 14001 (Environmental Management) for all our Europe, US, Russia and CIS Plants.
- ISO 50001 (Energy Management) for all our Europe, US, Russia and CIS Plants.
- ISO 9001 (Quality Management) for all our Europe, US, Russia and CIS Plants
FROM ROAD TO RAIL IN THE CZECH REPUBLIC
At our Krupka plant, Czech Republic, we switched from road to rail and saved 424 tons of CO2 equivalent in the first 15 months. The savings occurred after the plant transferred its distribution of products to Turkey and Romania from road to rail. By using the electric rail network and giant jumbo wagons that have double the capacity of road trucks, the company now needs half the number of trips for distribution. Over the 15-month period, transportation distances of 1.3 million kilometres were slashed in half and the total amount of CO2 equivalent was cut from 621 tons to 197. The saved CO2 of 424 tons is equal to the emissions output from an average car driving around the world a hundred times.
The first step was the installation of smart technological solutions that could measure daily energy use and show operators if they were within the set operating range of an historic best energy usage known as the ‘Energy Target’. The energy management system flags up exceptional usage for any single material manufactured at the Krupka line. Today, through the system, operators are immediately aware of their impact on energy use. Now, an operator can explain exactly what happened in minute technical detail if there’s a surge, which in the past was not the case. Operators know how much energy is used, why and how to control. Not only does the system monitor behaviour, but individual team performance as well. Of the four shifts in the plant the energy management system revealed that one was out-performing the rest. Through conversation and data analysis it is easy to see where there were challenges that caused extra energy use and what action was taken to improve that situation. Behaviour lessons learned from the more efficient shift can be shared with others, and behavioural patterns learned from those that are not as efficient can also be understood and changed. The biggest learning to be taken away from this is that perators are key. By the time management learns of a surge in energy use, that energy has already gone. Operators can make a difference the minute a situation occurs. The role of leadership or management is to provide education, awareness and tools.