Energy efficiency

improvement in a plastics
processing company

HOW TO REDUCE ENERGY COSTS

Guide for Entrepreneurs

Can modernisation of machinery and

technologies in a plastics processing
company be cost-effective?
Polish entrepreneurs are well aware of growing energy
costs. Social attitudes to environmental degradation
are also increasing the will to promote and introduce
energy efficiency.
During the first edition of the PolSEFF programme
Polish entrepreneurs implemented Investment projects
in the years 20112014. They have shown that the plastics
processing industry consumes a lot of energy. As a result
of investments the energy savings reached up to 75%.

What are the key elements in

plastics processing projects
that bring the highest benefits?

This brochure was created to present standard types of

investments in the plastics processing sector as well as
the benefits of investing.
The examples shown are based on real projects implemented by the PolSEFF programme.

The table below presents examples of investment

projects implemented by SMEs from the plastics
processing sector that brought a minimum of 20%
energy savings.

Replacement of 6 injection machines

with increased annual production
volume of 2,757,000 units

Replacement of a hydraulic
injection machine with annual
production volume of 180 tonnes

Savings: 76,000 PLN annually

Savings: 45,000 PLN annually

Replacement of an extruder with

annual production volume of
162,000,000 pieces with a new more
efficient one with annual production
volume of 288 million pieces
Savings: 77,000 PLN annually

Replacement of an injection
machine with a new hydraulic
one with VSD with the same annual
1800 tonnes output

Replacement of an injection
machine with a new servo-drive
hydraulic one with the same
annual 400 tonnes output

Savings: 370,000 PLN annually

Savings: 75,000 PLN annually

When is modernisation of
technologies in the plastics
processing sector most profitable?

Replacement of a blowing machine

with annual production volume of
92,300 tonnes with a new more
efficient one and increased production volume to 150,000 tonnes a year
Savings: 423,600 PLN annually

PolSEFF projects to modernise machines and equipment have shown that significant energy savings can
be obtained by replacing the existing high energy
consuming machines such as injection machines,
blowing machines and extruders. Replacing the old
models with new, more energy efficient ones brings not
only significant energy savings but also higher production
capacity, shorter cycles and better product quality.

Examples of modernisation investments in the plastics processing industry.

Investment
description

Investment details

Additional information

Investment
cost

Replacement of
a hydraulic injection machine with
annual production
volume of 180
tonnes.

Purchasing and installing

a new hydraulic injection
machine with annual production volume of 180 tonnes.

Electric injection machines are energy efficient because they

have a separate system designed for each operation in the
injection process. It consumes optimal amounts of energy for
each action making it more efficient.

300,000

62%

Replacement of
a hydraulic injection machine with
annual production
volume of 400
tonnes.

Purchasing and installing

a new hydraulic injection
machine with annual
production volume of
400 tonnes.

Hydraulic injection machines with servo drive are energy

efficient because the drive operates with optimal power
during key operations of the injection process.

600,000

58%

Replacement of a
hydraulic injection
machine with
annual production.
volume of 1800

Purchasing and installing

a new hydraulic injection
machine with annual
production volume of
1800 tonnes.

Injection machines with VSD are energy efficient because the

drive operates with optimal power during key operations of
the injection process.

1,600,000

54%

Replacement of 6
injection machines
with the annual
production volume
of 2,376,000 units.

Purchasing and installing

6 injection machines with
annual production volume of
2,376,000 units.

Introducing new robots to the production process causes

a significant decrease in the time consumed for each
production cycle. This change will also decrease the
consumption of energy.

705,000

75%

Replacement of a
blowing machine
with annual production volume of
92,300 tonnes

Purchasing and installing

a new blowing machine with
annual production volume
of 92,300 tonnes.

An old machine was produced in 1993 was being used

which caused poor product quality and had high energy
consumption.

5,060,000

42%

Replacement of an
extruder with annual
production volume
of 162,000,000
pieces.

Purchasing and installing new

machines with similar output.

The machines produce plastic drinking straws. Two machines

were in use producing poor product quality as well as lower
energy efficiency. The new machines use less energy and also
packed the straws in paper wrappers.

246,450

42%

Energy
savings
(%)

Financing modernisation investments

in the plastics processing sector
Investments in modernisation of machines, equipment
and production lines made by SMEs are financed
by the second edition of the PolSEFF programme.
The investor can use one of the following options.

Suppliers are welcome to register new products on the

LEME list. Instructions on how to register new products
can be found on the PolSEFF2 website in the section
For Suppliers.

When an investor is planning to replace an injection

machine with a new more energy efficient model
he can use the simplified procedure and choose the
machine from the LEME list. The list is available on the
website of the PolSEFF2 programme and it is regularly
updated with new products and categories.

The second option is the standard procedure that is

meant for complex projects. The investor is entitled to
cost-free technical assistance during the application and
evaluation process. More information about the standard
procedure can be found on the PolSEFF2 website.

Benefits of using the PolSEFF2 programme to

finance modernisation investments.
Being an entrepreneur, you may receive the following benefits
by participating in the programme:
Annual energy savings of at least 20%.
A grant of 10% or 15% of the loan amount used to finance
the eligible elements of the project. 15% is granted under
investments that require full energy audits of buildings.

Free support of Certified Energy Experts who assist in

completing the required application forms and conduct the
required technical and financial evaluation of the project.
The experts also provide energy audits and verify that the
investments qualify for financing.

PolSEFF2 the program for financing energy

efficient investments in small and medium
enterprises.
PolSEFF 2 is the second edition of the successful Polish
Sustainable Energy Financing Facility programme developed
by the European Bank for Reconstruction and Development.
It is implemented as a part of the NF Programme, which is
operated by the National Fund for Environmental Protection
and Water Management with support of the European Union.
PolSEFF2 is a EUR 200 million credit line made available to
participating banks. The banks then offer loans to SMEs for
financing energy efficiency investments.
More information about the PolSEFF2 programme is available
at www.polseff2.org/en.

Contact:
PolSEFF2 OFFICE
ul. Orzycka 27, 3rd Floor
02-583 Warsaw, Poland
Tel. +48 22 395 51 20
Fax +48 22 395 51 23
email: helpline@polseff.org
www.polseff2.org

WE SUPPORT AND FINANCE THE IMPROVEMENT

OF ENERGY EFFICIENCY IN YOUR COMPANY