Green Factories (procurement and production initiatives)
Saving Energy and Preventing Global Warming in Production Operations
Promoting Energy Savings at Production Sites
In line with its Green Factory certification system for comprehensively evaluating environmental activities at production sites, Konica Minolta strives to increase energy productivity and to reduce CO2 emissions from production operations through a variety of measures.
Energy Conservation Support Program
Konica Minolta has implemented an Energy Conservation Support Program in order to promote the reduction of CO2 emissions at production sites. Under this program staff members within the Group who are experts in process design, production equipment design, and energy management visit production sites and conduct inspections of everything from the energy management situation to the status of utilities and production equipment such as air conditioning and boilers, based upon which they recommend measures suited to each site. Using these recommendations, the expert staff and personnel at each site conduct simulations of the energy-saving effects, which help with implementing the measures.
Energy Conservation Support Program
Examples of Main Measures
|Improve productivity||Industrial engineering (IE) work analysis, yield rate improvement, installation of automatic machines, takt time reduction, production space optimization|
|Optimize equipment operation time||Shutdown during downtime, reduction of standby power consumption|
|Reconsider air conditioning operation||Temperature setting optimization, operating time optimization|
|Save energy in lighting||Thinning out lighting, conversion to high-efficiency lighting|
|Save energy in molding machines||Infrared heating, installation of servo motors, cylinder insulation|
|Save energy in compressed air||Installation of inverters, limited number of units, air pressure optimization|
|Reconsider refrigerator operation||Refrigerator integration, reconsideration of exit temperature setting|
|Use waste heat||Heat exchange at exhaust/intake, reduction of steam production by using waste heat from dehumidifiers|
|Reduce heat radiation loss||Steam piping insulation, piping integration, reduction of valve leaks|
Examples of Initiatives
Pursuing Energy Savings by Reviewing the Operation of Clean Rooms with High Energy Loads
(Konica Minolta Business Technologies (Dongguan) Co., Ltd.)
Konica Minolta Business Technologies (Dongguan) Konica Minolta Business Technologies (Dongguan) Co., Ltd., which manufactures MFPs and other products in Dongguan, Guangdong Province, China, has achieved dramatic energy savings by conducting reviews of the operational status of clean rooms with high energy loads in the factory. Specifically, it took another look at the temperature and humidity conditions while keeping them within product specification requirements, optimized the ventilation frequency while maintaining cleanliness, reduced clean room equipment operating time by installing a timer, and reduced clean room floor space through layout review. The implementation of these measures has saved energy used by cold energy source equipment and ventilation equipment.
These measures have greatly contributed to the 13th five-year plan and to the Excellent Green Factory Certification System, the Konica Minolta accreditation system launched in fiscal 2016.
Energy Savings through Smaller Production Space and Shorter Production Time
(Konica Minolta Business Technologies (WUXI) Co., Ltd.)
Konica Minolta Business Technologies (WUXI) Co., Ltd., located in Jiangsu Province, China, has adopted industrial engineering (IE) work analysis as a new endeavor aimed at reducing environmental impact through increased productivity. The analysis is based on specialized analytical knowhow cultivated in Japan by Konica Minolta. By thoroughly reconsidering operability and line of flow of production lines, the company reduced production space, shortened production times, and cut energy consumption, including that of air conditioning and lighting.
Konica Minolta Business Technologies (WUXI) Co., Ltd.
Utilizing Waste Heat from Production and Curbing Heat Dissipation to Ensure Energy Conservation (Konica Minolta Supplies Manufacturing Co., Ltd.)
With its head office in Kofu, Yamanashi Prefecture, Konica Minolta Supplies Manufacturing Co., Ltd. makes developers and photosensitive drums for multi-functional peripherals (MFPs). The company has achieved sharp reductions in energy consumption by utilizing the waste heat from the toner production process and curbing the heat dissipation from steam pipes.
Heat exchange with high-temperature water is typically used, but the company actively uses the waste heat from low-temperature water generated in the toner production process through heat exchange and produces heated water to be used in other processes. This significantly reduces the gas consumed to produce heated water.
The company also installed an automated control system to supply steam only when and in amounts needed to prevent heat from dissipating from the pipes.
Kofu head office at Konica Minolta Supplies Manufacturing Co., Ltd.
Pursuing Energy Savings with a High-Efficiency Air Conditioning System
(Konica Minolta Business Technologies (Malaysia) Sdn. Bhd.)
Konica Minolta Business Technologies (Malaysia) Sdn. Bhd., which assembles MFPs, has achieved major energy savings by actively employing high-efficiency air conditioning systems.
Since Malaysia is a tropical country where air conditioning use is high, the company has installed a large-temperature-difference air conditioning system and a temperature-stratified air-conditioning system and reduced electricity consumption compared with conventional air conditioning.
In the areas between each factory building, dedicated individual air conditioners had been required, but individual air conditioners were discontinued by supplying surplus cold air from air conditioners in other processes. In this way, the company has promoted high-efficiency air conditioning operations throughout the plant.
Konica Minolta Business Technologies (Malaysia) Sdn. Bhd.
TOPIC: New Environmentally Friendly Research Building SKT
The new R&D building (SKT) opened in April 2014 at Konica Minolta Tokyo Site Hachioji integrates environmental facilities that will contribute to environmental impact reduction, including solar panels on the roof, an atrium that brings in lots of natural light, daylight sensors to reduce lighting electricity consumption, effective natural ventilation, and use of well water. As a building with excellent environmental friendliness, SKT received the highest certification, “Class S,” in the Comprehensive Assessment System for Built Environment Efficiency (CASBEE), which is an evaluation of the environmental performance of buildings led by Japan’s Ministry of Land, Infrastructure, Transport and Tourism. The building also won a fiscal 2014 Good Design Award from the Japan Institute of Design Promotion (JDP).
TOPIC: Installing a Gas Turbine Cogeneration System That Provides High Energy Efficiency by Effectively Using Exhaust Heat
On February 1, 2017, the Konica Minolta Kobe Site began operating a gas turbine cogeneration system that uses city gas as fuel. This system provides distributed power generation (7,000 kW class power generation output) that generates power in the places where energy is needed. By effectively utilizing exhaust heat generated at that time, it is possible to achieve overall efficiency at a high 80-90% energy efficiency (general thermal power plants are at about 40%), which greatly contributes to energy saving and CO2 emission reduction.
This system is superior from the standpoints of both energy saving and environmental preservation because the fuel uses city gas with high combustion efficiency and low impurity, generates virtually no dust or sulfur oxides, and generates low amounts of nitrogen oxides thanks to the latest low-NOx combustion technology.
When it was installed, it was assessed as a Class 2 Project, the first such project under the city of Kobe’s environmental assessment standards. The preliminary considerations of the environmental impact assessment were also disclosed to stakeholders, a briefing was held, and opinions were taken into account.
Primary Advantage of Installation
CO2 reduction: CO2 reduction of 20% or more compared with previous methods
Peak cut: Leveling of electricity demand: Electric power peak cut rate is 70%
BCP: The system supplies power to the premises critical load in the case of emergency
Subsidies: Subsidy support was received from the Energy Use Rationalization Business Support Program, in recognition of the high energy savings of the installed equipment.
At this site, the company has continued to install energy-saving equipment, streamlined product manufacturing processes, and achieved per-unit reductions of energy consumption by an annual average of 4% or more. The operation of this system is positioned as the core of the energy saving and CO2 emissions reduction plan in the Medium-Term Environmental Plan 2019.