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PAC: Package Converter, Process/Facility - Silver

Water Saving Project

Overview

An Alcan team consisting of a project engineer, process engineer, operations manager, technical manager, EHS manager, and site director were brought together to work on the initiative. They developed and installed an innovative reservoir-less design to minimize the amount of water in the chill system and reduce ongoing water usage. Alcan Packaging Toronto reduced water use at the plant by 80% through the design, sourcing and installation of an innovative new chill system. This saving resulted in a reduction of water consumption of over 45 million gallons per year. The city of Toronto awarded them the largest payment through its corporate challenge program for saving water, in the program's history.

Motivation for Change

The reduction in water usage resulted in a cost reduction. There was strong encouragement by Alcan Inc. to pursue Environmental Health & Safety initiatives (EHS) employing our proprietary Continuous Improvement (CI) process.

Cost Effectiveness

The City of Toronto through its Toronto’s Corporate Challenge Program pays industrial commercial and institutional customers a one-time fee of $0.30 per litre of water saved as a result of capital upgrades. The City presented a cheque for $166,960.30 to Alcan Packaging in January 2007 as a result of this water savings project. This is the largest payment awarded to any customer in the program’s history.

Performance

A single chiller supplies three separate production lines, each with an independent operation schedule. The chiller provides each process with the correct amount and temperature of cooling water, all within a closed loop system and with minimal intervention. Along with other innovations, a re-circulation loop on one of the production lines ensures maximum heat transfer and further decreases the use of cooling water. Premium efficiency electric motors on the pumps minimize ongoing electrical costs.

Community Benefit

The project has been nominated for the city’s “Green Toronto” award.

Resource & Energy Optimization

Alcan Packaging Toronto reduced water use at the plant by 80% through the design, sourcing and installation of an innovative new chill system. This saving resulted in a reduction of water consumption of 45,257,322 gallons per year.

Categories: PAC Award Winner General Packaging Facility/Process

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