At a Glance

JFC Manufacturing is a global

organisation, which is renowned
worldwide for its quality plastic
products.

2010-ET-CP-17
Investigation into energy reduction and
recovery at JFC.

The company introduced a number of

environmental initiatives as a result of
participating in the Cleaner Greener
Production Programme.
The aim of the project was to reduce
energy consumption and waste arising
within the company. The company also
incorporated eco-design initiatives to
optimise
material
and
energy
consumed in product manufacturing.
As a result of the project the company
has made significant savings, with total
combined savings of 63,362.

JFC Manufacturing
Weir Road, Tuam Co Galway, Ireland.
Website www.Jfc.ie
JFC manufacturing was set up in 1987 to
supply a wide range of specialised plastic
products
such
as
agricultural,
construction, bottle banks and marine
products. The company currently employs
over 200 staff.
Aim of this project

Energy savings achieved through

monitoring and measuring electricity
consumption.
27% electricity reduction per kg of
pipe produced.
Electrical
motor
saving
of
6035Kwh/year saving 844 per
annum.
Energy saved via compressed air
savings of 14815Kwh per annum or
2000 per annum.
8% reduction in gas consumption
by sealing oven doors.
Eco-Design savings resulting from the
new Fast Fill Water Trough
Equivalent of 26% less plastic is
used to manufacture the water
trough while maintaining quantity.
End of life of the product improved
due to elimination of metal
components.
Plastic clips make the new product
100% recyclable.
JFC staff trained in environmental
awareness.

The end of life of the product, also has

improved due to the elimination of metal
components been used for the trough
cover. Plastic clips have been designed into
the new product making it 100% recyclable.
All stick on labels have been removed as all
labels are now etched into the product.

The main aims of the project were:

To reduce energy consumption
throughout the facility.
Incorporate eco design initiatives into
water troughs.
Reduce waste through further reuse
of material.
Product Description
The CGPP team at JFC Manufacturing
undertook a review of energy, waste and
material consumption. Following on from
consultation with a number of suppliers
the team sought input on new design
ideas from engineers on energy and
waste minimisation opportunities.
Eco design
Eco design initiatives were incorporated
into the new design for the Fast Fill Water
Trough. The equivalent of 26% less plastic
is used to supply water to the same
number of cows.

New labelling on new Fast Fill water trough

Outcomes
Energy saving
An energy monitoring programme and
measuring
electricity
consumption,
achieved a number of savings.
Electrical motors monitoring
Single phase units were monitored and
simple initiatives like putting timers on
vending machines, turning off boilers at the
weekends and turning off unused items
brought in savings of 6035Kwh/year (3198
Kg CO2) or 844.
Compressed air savings
After attending several energy seminars it
became apparent that compressed air was
a viable area to save energy. A compressed
air audit was undertaken and 19 leaks were
repaired. This has an estimated saving of
14815 KWh (7851 Kg CO2) or 2000 per
annum.
Pipe manufacturing
Electricity use per kg per pipe
manufactured has decreased significantly.
The graph below shows the improvements
made.

After waste management training

recycling rates began to increase. As
seen in the graph recycling has
increased by 63% since August 2011
throughout the facility.
Due to the recycling programme and
the use of regrind material a total of 73
tonnes was diverted away from landfill.
Training
Gas reduction
The energy team was aware that the
second biggest energy expenditure was
due to the use of LPG in the production of
products as part of the rotational moulding
process. The most effective method to
reduce gas consumption was to reseal and
insulate the oven doors to the highest
standards. This was completed in 2011 and
savings of around 8% thereafter were
apparent.

Environmental awareness training was

given to the staff at JFC. Fifty personal
were trained on waste recycling,
twenty on energy reduction measures
and four on eco design of products.
Observations
Overall the CGPP project contributed
to significant savings for the company.
The eco design initiatives can be
incorporated into a range of other
product at JFC.
Energy and waste saving opportunities
are on-going within the organisation.
Environmental awareness training was
presented to all staff to ensure the
initiatives under CGPP are incorporated
into the company for the future.
Lessons Learned

Pulveriser Efficiency Project

Throughout the course of the CGPP JFC has
focused on increasing the use of recycled
plastic. This has led to an increased
demand on the pulveriser. After a month
of experimentation and trials an increase in
throughput from an average of 240kg/hr to
430kg/hr was achieved. This showed that
the cost of running the pulveriser was
9.50/hour and approximately 69kw/h.
Thus the EPI of the pulveriser shows an
improvement of 3.47 Kg/Kwh to 6.23
Kg/Kwh a saving of 2.76 Kwh/kg (1.46 Kg
CO2/kg) of material put through the
pulveriser.
Waste minimisation
Under CGPP JFC introduced a waste
recycling programme. The amount of bins
collected in 2010 compared 2011 is
illustrated below.

Many lessons have been learned

during the CGPP project.
Communication among staff and
customers on potential savings was
extremely beneficial.
Environmental awareness training
allowed staff to understand the
objectives of the company.
More Information
For more information on this project
please contact:
Norman Black
JFC Manufacturing
Weir Road, Tuam Galway, Ireland
Tel: 093 24066
Email: nblack@jfc.ie

The
Cleaner
Greener
Production
Programme (CGPP) of the EPA is funded
under the National Development Plan
2007-2013. The CGPP was launched in
2001 as a grant scheme to fund Irish
organisations to implement cleaner
greener
practices
while
achieving
significant cost savings.
Cleaner Greener Production is the
application of integrated preventive
environmental strategies to processes,
products and services to increase overall
efficiency and reduce risks to humans and
the environment.
Production processes: conserving raw
materials and energy, eliminating toxic
raw materials, and reducing the
quantity and toxicity of all emissions
and wastes
Products: reducing negative impacts
along the life cycle of a product, from
raw materials extraction to its ultimate
disposal.
Services: incorporating environmental
concerns into designing and delivering
services.
The programme aims are focussed on
avoiding
and
preventing
adverse
environmental impact rather than treating
or cleaning up afterwards. This approach
brings better economic and environmental
efficiency.
The CGPP is funded by the EPA STRIVE and
NWPP programmes

Additional case studies from companies

that participated in CGPP are available on
our website (www.cleanerproduction.ie),
including:
Programme brochures, summarising
all projects funded under CGPP
More information on CGPP is available
from the EPA:
Lisa Sheils
Environmental Protection Agency,
Richview, Clonskeagh,
Dublin 14, Ireland
Tel: +353 (0)1 2680100
http://www.epa.ie/researchandeducation/research