Date Published: 02/2013

Techno Plas is an Australian-owned plastics and specialist moulding manufacturer based in South Australia. The company operates a highly automated manufacturing facility, incorporating laser-guided vehicles capable of running the entire production process with minimal intervention, from granulated plastic resin stored in silos through to fully packed and labelled products in the warehouse.

Highly skilled technical and project management teams have enabled much of the facility's automation to be developed in-house. The manufacturer has built a reputation for delivering successful product development and project management services, from tooling design through to production. Techno Plas supplies major Australian companies and has achieved efficiencies that enable it to export commodity plastic products to China.

Techno Plas was named the 2001 Telstra South Australian Small Business of the Year and was also National Runner-Up in the Telstra Innovation Awards.

Drivers for Sustainability

In 2011, Techno Plas engaged Pangolin to undertake an Energy Audit to better understand the organisation's energy consumption.

As an energy-intensive manufacturer facing rising electricity costs, Techno Plas wanted to identify:

• Where energy was being used across the business.
• The associated operating costs.
• Opportunities to reduce both energy consumption and expenditure.

Sustainability Actions and Energy Efficiency Funding

Equipment Upgrades and Grant Funding

Using recommendations from Pangolin's Energy Audit, Techno Plas successfully secured $212,740 through the Australian Government's Clean Technology Investment Program.

The funding supported the replacement of approximately 20% of key manufacturing equipment. As a result, more than 50% of raw material is now processed using equipment that delivers average energy savings of approximately 60%.

Greenhouse Gas Assessments

Techno Plas has engaged Pangolin Associates to undertake annual greenhouse gas assessments since FY2009-10. These assessments allow the company to accurately measure, monitor and reduce its carbon footprint year on year.

Building a Sustainability Culture

The organisation has developed a workplace culture focused on sustainability and continuous improvement. Awareness of energy efficiency extends from the boardroom to the factory floor. As Joint CEO Stefan Billing explains:

"The factory floor is seeing a physical commitment to sustainability, not just talk. It creates pride for all of us."

Sustainable Decision-Making

Sustainability considerations are integrated into many aspects of the business, including capital purchasing decisions and operational planning.

Results

Through the implementation of audit recommendations and equipment upgrades, Techno Plas identified that the performance of integrated equipment systems was more important than individual components alone.

The company has achieved energy savings of between 50% and 60% per kilogram processed on specific machines and associated equipment. Across the entire manufacturing facility, Techno Plas reduced its carbon footprint per kilogram processed by 18% over a three-year period. These achievements have encouraged the company to continue identifying new opportunities for efficiency improvements and emissions reductions.

Business Sustainability Alliance (BSA) Energy Efficiency Funding

Techno Plas, along with several other Pangolin clients in South Australia, received Business Sustainability Alliance (BSA) Energy Efficiency funding to support energy audits and training. The BSA was an initiative of the Department for Manufacturing, Innovation, Trade, Resources and Energy, SA Water, Zero Waste SA and the Environment Protection Authority.