Energy efficiency in the juguetero sector

Within this context, the Research Association of the toy industry, related and Allied (Aiju), in an effort to alleviate environmental problems of the sector and as technological support, continues the road opened with the draft sectoral diagnosis of industrial ecosystem of the 'Foia de Castalla'. EcoINNOVA Joc, carried out within the call of the programme of promotion of innovation 2007 and 2008 of Impiva, which envisioned the State in the environmental management of the companies in the industrial fabric of the 'Foia de Castalla'so that is defined innovadoras-estratégicas lines of research and which included sustainability, as an important element (I+D+i+S), and where Aiju should continue to be the environmental technological engine sector and local businesses.

The basic purpose of this initiative is to the promote the development of environment friendly processes, more specifically those most representative processes of the industrial fabric of the 'Foia de Castalla,' as a focal point of the juguetero sector at the national level and thus of the Valencian Community. The improvements have faced from the point of view of the improvement of the energy efficiency of these processes. This has been done a more in-depth study on the habits of consumption and practices associated with this type of process, as well as a more comprehensive survey of all those technologies and best practices that are being implemented in other sectors and other companies and extrapolated to the companies in the juguetero sector.

The main objective of this publication has been the disseminate initiatives and possible practices to increase energy and therefore efficiency enhancing a more responsible energy use in enterprises of the industrial fabric of the 'Foia de Castalla' so identified opportunities for improvement, easy implementation and which have an impact on significant economic savings in the medium term. In this way has a corporate and institutional awareness which promotes:

This has been a study to know in depth energy consumption habits (calculation of the ecological footprint) and more efficient technologies that are being used in the industrial fabric of the 'Foia de Castalla' (for example)(, using productivity economizer of electric power or catalysts to boilers).

The awareness of the sector with the introduction of good environmental practices associated with the reduction of energy consumption. So it has to the sector of a source of information on energy-saving initiatives carried out in other sectors, as well as emerging technologies that can be implemented in the industrial processes.

The diffusion on the working methods and technologies available on the market and implemented by other sectors aimed at optimizing the use of energy today.

Innovation applied to sustainability, through a study of the improvement proposals arising from the information obtained.

With this initiative Aiju joins lines from other agencies are carrying out to do his bit to comply with the basic target set in the Plan of savings and energy efficiency of the Valencian Community so that it reaches the next horizon of forecast (Figure 1).

1. Reduction of energy consumption final of the Valencian Community in such a way that will reduce final energy intensity in all economic sectors.
2. Reduction of energy consumption primary of the Valencian Community in such a way that will reduce the ratio of total primary energy per unit of GDP.
3. Improving the competitiveness of Valencian companies, reducing energy costs through the introduction of more efficient technologies.
4. Reduction of energy dependence of the Valencian Community to the outside.
5. Reducing the environmental impact, using cleaner energy in order to comply with the commitments made by the whole of the European Union at the Kyoto Summit.

2 There is a high awareness of the need to reduce costs of production to increase the competitiveness of products made in the industrial fabric of the 'Foia de Castalla'.

3. Still exist quite some diversity of production processes, there are possible lines of energy improvement aimed at optimising production processes, lighting, air conditioning, displacement and logistics, as well as the use of Office and electronic equipment and the introduction of renewable energy.

4. Many technologies and good practices tested in viable way in other enterprises or sectors can be applied to the companies in the industrial fabric of the 'Foia de Castalla' have been detected.

5. In recent years has been detected a noticeable tendency to make photovoltaic installations on the roofs of the warehouses, all of them connected to the network of electricity supply so that they inject the energy produced. Currently there is high interest in continue to make such facilities, as well as there are useful surface of the roof to do so, although it has decreased the affordability of such facilities by the lack of subsidies and the reduction in premium sold photovoltaics.

According to the study, the industrial fabric of the 'Foia de Castalla' has a high awareness on environmental issues and a pressing need to reduce costs associated with the production and the normal operation of the facilities. However, some habits of consumption and practices that can improve considerably and for what they are going to define a set of strategies for the future, to increase the energy efficiency of the industrial fabric of the 'Castalla Foia' are detected, so that is consistent with the principles of the research, development, innovation and, of course, with environmental sustainability (I+D+i+S).

Future strategies must be linked to the increase in efficiency and energy savings in measures related to:

• Use of fuels and energy sources
• Process equipment
• Lighting
• Air conditioning
• Mobility of employees and logistics
• Use of Office and electronic equipment
• Use of renewable energy

Definition of actions

1. Realization of diagnostics/audits energy.
2. Appointment of a person responsible for energy management.
3. The reactive power compensation.
4. Optimization of electricity bills.
5. Optimization of natural gas bill.
6. Optimization of diesel fuel Bill.
7. Use of fossil fuels (gas-oíl / natural gas) for the process of heating baths galvanic replacing the electrical resistance.
8. Replacement of diesel C/fuel oil as a fuel for natural gas in boilers and furnaces of drying.
9. Installation of cogeneration equipment.
10. Utilization of residual heat.
11. Awareness, awareness of the staff.

Definition of actions:

1. Shutdown of equipment and assistants when they are not operating.
2. Recharge of batteries of electric truck at night.
3. Optimizing use of motors of more than 5 kW.
4. Optimizing use of compressed air.
5. Incorporation of electric or hybrid injectors from the conventional hydraulic.
6. Optimization of the injectors.
7. Optimization of the extrusion machines
8. Optimization of blowing teams.
9. Optimization of rotational molding equipment.
10. Optimization of thermoforming equipment.
11. Use of rectifiers of last generation (IGBT) in the process of coating by electrochemical means.

Definition of actions:

1. Use of natural light.
2. Replacement of the lighting system.
3. Optimal maintenance of the lighting facilities.
4. Implementation of General support measures in lighting.

Definition of actions:

1. Better insulation of the building.
2. Replacement of the air conditioning system.
3. Optimal maintenance of air conditioning installations.
4. Implementation of General support measures in air conditioning.

Definition of actions:

1. Optimization of the fleet of vehicles.
2. Use of less polluting vehicles.

Definition of actions:

1. Activation of the system of automatic shutdown on computers.
2. Activation of the 'Stand-by mode in the photocopiers.
3. Consideration of criteria of energy efficiency in the procurement of computers and office equipment.
4. Use of screen saver without animation.

Definition of actions:

1. Investment in photovoltaic installations.
2. Use of thermal solar energy as a support for the warming of galvanic baths and other processes with heat demand.
3. Investment in wind power plants.