Orora is committed to driving resource efficiency in its everyday operations through its long-running resources efficiency program.
We work closely with our manufacturing sites to identify opportunities for improvement in driving resource efficiency and actively share the learnings across our broader operations.
Through regular internal benchmarking of similar sites (by product mix, volume, plant and area), as well as benchmarking across industry where data is available, sites are selected for an in-depth resource efficiency audit.
The audit looks at processes, procedures, operating environment and resource use to create a detailed site map that specifies areas for improvement.
In collaboration with site personnel, including site and production managers, maintenance, engineering and frontline team members, improvement projects are identified and scoped.
The final outcome is a detailed list of both easy-to-achieve goals and more long-term, complex solutions that each site uses to prepare project plans for implementation.
Improving waste water treatment at Scoresby Fibre Packaging
Our Fibre Packaging facility at Scoresby in Victoria, Australia has reduced its hazardous waste output by 95% and water use by 20 kL per day.
In partnership with Syntek Environmental, a specialist in wastewater treatment and reuse, Orora commissioned a new wastewater treatment plant. EcosynergyTM and UltraverteTM biological treatment processes convert soluble and insoluble waste into bio gas, with the remaining solids having much reduced concentrations of hazardous materials.
This best-in-class biological treatment technology replaces an outdated chemical treatment approach, eliminating the use of heavy metal-containing coagulants and polymers to separate printing waste and starch solids, and the creation of hazardous solid waste.
Reducing energy use at Wiri Beverage Cans
The team at Orora’s Beverage Cans facility at Wiri in Auckland, New Zealand has made a long term commitment to reducing its energy use. Procedures were introduced to ensure equipment ran only when required and numerous Variable Speed Drives (VSDs) were fitted on transfer fans. Increasing the volume of cans on a conveyor reduced the level of vacuum suction needed, as more cans cover more holes. When combined with process optimisation, energy use fell by 30% in the first two years.
This success led to further investment in insulation, linking the site’s two boilers so that only one needed to run, and using hot water instead of electricity to keep coolant at the desired temperature. Two new VSD air compressors were introduced, allowing the air system to be split into high and low pressure systems.
Today, Wiri uses almost 50% less energy and work continues to reduce energy use with factory LED lighting installed and additional insulation planned. In May 2016, these achievements were recognised by the New Zealand Energy Efficiency and Conservation Authority, who presented Orora’s Wiri Beverage Cans the Large Energy User Award.