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EnergyBall Packaging Europe consumed 728 gigawatt hours (GWh) of energy in 2009. While production volumes increased by more than 6 percent between 2007 and 2009, energy consumption decreased by 4.2 percent. As a consequence, our energy efficiency, which we measure as per 1,000 cans produced, improved by 10 percent between 2007 and 2009 and has improved by 27 percent since 2003. Ball Packaging Europe’s goal is to further improve energy efficiency by 6.5 percent by 2011.
Chart: Percentage reduction of energy consumed per 1,000 cans produced We have implemented projects in all of our 12 plants to increase energy efficiency and decrease costs and greenhouse gas (GHG) emissions. These efforts include educational measures, improving operations and major capital investment projects such as replacing older existing equipment with more energy-efficient units. Technology and equipment Ball Packaging Europe invested more than €5 million in energy savings projects in 2008 and 2009. These investments will save approximately 29 GWh annually. We are using comprehensive Energy Information Systems (EIS) in all of our plants, enabling us to better understand and manage the energy consuming processes in our operations and improve total system performance. Electricity, gas and water measurement devices were installed on the most energy intensive equipment. Through advanced metering systems and software, real-time energy information and consolidated data for all machines are provided online. The EIS enables us to continuously measure energy efficiency and to better understand energy consumption in our complex manufacturing process. Performance of energy consuming equipment can be managed effectively and we are able to identify and quickly react to anomalies. By constantly monitoring and tracking energy consumption, we are also increasing awareness on energy efficiency and related costs. We estimate that the annual energy saving realised by the EIS is approximately 2 percent of our energy costs. Compressed air use is the most energy intensive process in our operations. Production motors, ovens, HVAC (heating, ventilation, air conditioning), vacuum pumps and chillers are other high energy consuming equipment. Our major focus is on optimising the performance of compressed air systems. We have reduced system pressure, minimized wasteful air uses and leaks, regulated volume and pressure and reduced demand by manufacturing equipment. A regenerative thermal oxidiser (RTO) is a pollution control system that uses high temperature to destroy volatile organic compounds (VOC) emitted during the can coating processes. It normally operates on natural gas. By installing VOC concentrators in the RTOs in our plants in Bierne, France, and Hermsdorf, Germany, we reduced annual natural gas consumption by 10 GWh, saving approximately 2,000 tons of CO2 emissions every year. Awareness and Employee Involvement Visibility and education are important factors for energy awareness. In many Ball plants employees are working diligently to increase energy efficiency. By doing so they attract the interest of others, raise awareness and motivate them to contribute. In our plant in Weißenthurm (Germany), employees formed an energy conservation team with engineers, group and shift leaders. Every day they analyse the efficiency of the main energy consuming equipment and identify and implement energy saving measures. For example they have started to re-utilise hot exhaust air in ovens resulting in a 12 percent gas reduction per oven. They have also conducted surveys on compressed air use resulting in lower electricity consumption of 830 megawatt hours (MWh) per year. From 2006 to 2009, the plant reduced its electricity demand by 22 percent per 1,000 cans produced and its gas demand by 24 percent per 1,000 cans produced. Benchmarking and Best Practice Sharing We benefit greatly from exchanging best practices among our sites and with other divisions of Ball Corporation. By learning from each other we strive for consistent and efficient processes across our operations. Team spirit and the exchange of knowledge are the cornerstones for the success of our energy reduction efforts. The EIS contributes to increased transparency and better benchmarking of our plants. Greenhouse Gas (GHG) Emissions Our primary effort to reduce GHG emissions is directed towards increasing energy efficiency. Between 2003 and 2009 Ball Packaging Europe reduced the CO2 emissions per 1,000 cans produced by 23%.
 Chart: Percentage reduction of CO2 emissons per 1,000 cans produced We also continue to explore cost-effective ways to use renewable energy. For example, we plan to install solar panels on the 34,000-square metre roof of our plant in La Ciotat, France. The annual electricity output will be approximately 1,350 MWh, thus avoiding 120 tons of CO2 emissions per year. We expect the first electricity to be delivered in the first half of 2011. *1 GWh (gigawatt-hours) = 1.000 MWh (megawatt-hours) = 1.000.000 kWh (kilowatt-hours)
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