Smurfit Kappa

Smurfit Kappa is the world’s leading producer of paper-based packaging, with around 38,000 employees and a sales revenue of more than $100 billion in 2011. EnergyCAP SmartAnalytics™ helps Smurfit Kappa identify electricity-saving opportunities for one of their GopFert die cutters. With 400 production lines in 31 countries, significant saving opportunities are targeted.

Installation setup

A 3-phase meter was wired to the main incomer of the distribution board powering up the GopFert units, and once-off software profiling was conducted to record the machine’s power levels in each operational stage.

EnergyCAP SmartAnalytics Insights

1. Vacuum unit left on when no boards are processed (EnergyCAP SmartAnalytics Breakdown uncovered that operators forget to switch off vacuum unit when switching printing jobs)
2. Machine left in Idle mode over the weekend (Breakdown helped calculate savings to be achieved during the weekend if the machine is switched off)
3. Operators real-time alerts for consumption anomalies via the deployment of v Smart Alarm (Smart Alarm deployed and triggered by Breakdown engine whenever the vacuum is left on unnecessarily)

The Results

After 11 weeks of monitoring, results showed an average 50% reduction in electricity cost for the vacuum unit, representing a 10–15% decrease in the production line’s overall cost. Projected return on investment within one year based on savings achieved.