Glass & Solar
Vetropack Holding AG
Bülach Switzerland
Completion: 2021
Bülach
Bülach,
SwitzerlandGiven the well-known fact that glass production is extremely energy- and
cost-intensive, many adjustments need to be made in order to achieve
improvements in both areas. And this would be impossible without the use of
professional software tools, especially in light of Vetropack’s goal of
ensuring uniform energy management across all its locations. Another challenge
is the definition, harmonization, and uniform reporting of energy measurement
points with the involvement of Controlling.
Objective - to comprehensively manage energy throughout the Vetropack
Group, from planning and strategic procurement to monitoring consumption and
invoice verification.
- Energy Management System: SIMATIC Energy Manager PRO and add-ons for structured energy procurement
- Automation Systems: DCS SIMATIC PCS 7 and SIMATIC S7 PLCs - ET200 SP HA
- Metering devices and instrumentation: SITRANS FX330, SITRANS FS 220 for natural gas, compressed air, water; SENTRON PAC 3200/4200 for electrical energy
- Services: from advice and analysis in joint workshops to installation, commissioning, and project planning of energy management software solutions.
What’s special about Vetropack’s approach is that a core project team is devoted to the task of tackling energy management from the perspective of both commercial and technical factors as an integral part of the company’s digitalization strategy. The project was initiated and is led by Strategic Procurement. The packaging glass manufacturer believes that the best and only way to optimize energy consumption and energy costs at the Group level – and thus make the necessary contribution to improving the company’s CO2 footprint – is to link all disciplines involved, from production and engineering to procurement. After a phase of evaluating and piloting different systems, the longtime Siemens customer chose the Simatic Energy Manager PRO software solution. Siemens and Vetropack piloted the system in the Austrian factory in Kremsmünster in 2019 before systematically embedding it into the existing Simatic PCS 7 and IT infrastructure in all the other factories, beginning with the factory in the Croatian town of Straza.
“As we see it, Siemens plays a pioneering role
in comprehensive energy management solutions. In addition, we’ve been very
impressed with the company’s expertise in the glass industry. On top of that,
their team is highly experienced, and the same team has supported us for many
years and is always very flexible.”
Kurt Hagenberger, Lead Buyer Energy at Vetropack Austria GmbH
With Siemens, Vetropack has a partner at its side who can completely map
energy management in all dimensions, from consulting to implementation. Added
to this is Siemens' specific experience in the glass sector as well as its
fundamental know-how for electrification, automation and digitalization.
Highlight: Smart energy procurement with real-time price display
Vetropack could well be the first company to link an energy management system with a fully integrated energy procurement tool. As a result of these measures, Vetropack can connect all market data in real time to the newly developed add-on of SIMATIC Energy Manager PRO and represent its entire procurement strategy and the implementation of that strategy in the module.
Highlight: Smart energy procurement with real-time price display
Vetropack could well be the first company to link an energy management system with a fully integrated energy procurement tool. As a result of these measures, Vetropack can connect all market data in real time to the newly developed add-on of SIMATIC Energy Manager PRO and represent its entire procurement strategy and the implementation of that strategy in the module.
- All market data, procurement schedules, and procurement quantities are recorded and graphically displayed. Consumption values are likewise integrated graphically.
- The graphic display follows the established procurement strategy. The status quo of all factories can be seen at a glance.
- The tool manages energy package purchases for the purpose of structured procurement in line with the strategy. Setting target prices triggers notifications in the form of action recommendations whenever the price targets are approached; alternatively, target prices can be agreed on directly with the energy supplier.
- Purchase quality is monitored graphically relative to self-defined benchmarks.
- Budget calculations and subsequent refinements on the basis of periodic forecasts are supported and quasi-automated by the system.
- All energy procurement contracts are administered in the system. The bids submitted in tenders are simulated using the relevant contract criteria. This allows the lowest-cost variant for implementing the strategy to be identified quickly.
- The CO2 emissions from energy consumption and batch formulation, including Scope 2 CO2 emissions, can be calculated in this tool. The necessary certificates and their acquisition are likewise integrated into the tool.
- Thanks to the display of real-time prices (both hedging and spot prices), the decision to change and optimize the energy mix (electricity vs. gas) can be made at any time.
Headquarters Bülach and production plants in Hum na
Sutli, Gostomel, Nemsova, Kyjov, Kremsmünster, Pöchlarn. As a leading manufacturer of glass packaging for the food and beverage
industry in Europe, the Vetropack Group relies on SIMATIC Energy Manager PRO
for both energy management and the systematic procurement of energy.
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