Projects

Citation

(2011), "Projects", Circuit World, Vol. 37 No. 4. https://doi.org/10.1108/cw.2011.21737dab.014

Projects

Article Type: Appointments From: Circuit World, Volume 37, Issue 4

SurfEnergy energy efficiency advisor-free energy saving tools for PCB manufacturing

The SurfEnergy project supports the introduction of energy efficiency measures by small and medium enterprises (SMEs) in the PCB manufacturing industry sector. The aim is to increase the awareness of manufacturing companies to the introduction of energy management systems and the potential benefits that could result. The project addresses non-technological barriers to the implementation of efficient energy management in this SME-dominated sector. The project also covers energy efficiency in the surface finishing sector.

The main interface between the project and SMEs will be through an energy efficiency advisor toolkit found on the SurfEnergy web site (www.surfenergy.eu). This toolkit is specifically targeted at the relevant industry sectors and enables users to reduce energy consumption, reduce costs and make informed decisions on investments. Supported by Intelligent Energy Europe, the advisor tool is provided by SurfEnergy free of charge.

Production methods involved in PCB manufacturing and surface finishing are very complex with some factories having as many as 800 different processes. Therefore, an extensive set of tools, methodologies and information has been developed to cover all aspects of these industries, including energy management systems, measuring and analysing performance, energy-saving opportunities, forecasting and investment decision making. To enable easy access to all these items, a logical graphical interface has been developed to guide the user through the process. The SurfEnergy path to energy efficiency (Figure 1) allows the user to work from one stepping stone to the next, at each stage collecting information or completing the interactive functions. By the time the user has reached the end of the path, they will have all the necessary tools to make real energy savings to their business.

Figure 1 SurfEnergy path to energy efficiency

Moving along the path to energy efficiency, the steps help the user in the following ways.

Setting up an energy management system

Ad hoc changes to operation in an attempt to save energy will typically only make temporary improvements. In order to sustain energy consumption over a long period of time, a formal structured energy management system is vital. Commitment to an energy management system must be made at all levels of the company, with full awareness of the requirements throughout the organisation.

Existing methodologies such as ISO14001 and EN16001 provide a good starting point, promoting continual improvement in energy management (Figure 2) through a plan-do-check-act process. They also enable the establishment of an accredited system which can be used to promote the company. SurfEnergy describes how to incorporate this into the PCB and surface finishing sector to achieve results without large amounts of effort.

Figure 2 Continual improvement through energy management

Energy auditing requirements

Carrying out an energy audit to ascertain the current performance of the organisation is a key part to energy strategy to quantify continual improvement. Through consultation with project experts and carrying out many audits within the project, the optimum method for the PCB and surface finishing industries has been identified. The main steps to this audit are shown below, and full details are presented in a report downloadable from the web site:

• •

  Phase 1: collection of initial information.

• •

  Phase 2: visit to the factory.

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  Phase 3: technical analysis of the energy situation in the factory.

• •

  Phase 4: energy efficiency measures proposal.

• •

  Phase 5: technical report.

Measure lists and key performance indicators

To complement the auditing requirements, a list of data requirements has been drawn up for each process type. For PCB manufacturing, the complex tasks can broadly be split into nine categories as follows:

1. 1.

   drilling;

2. 2.

   primary imaging;

3. 3.

   lamination;

4. 4.

   PTH technology;

5. 5.

   etching;

6. 6.

   soldermask;

7. 7.

   final finishing;

8. 8.

   inspection and testing; and

9. 9.

   water treatment.

For each process the required measurable parameters for analysis are provided, e.g. annual production (m²/year) or electrical energy consumption (kWh). From the studies in the project the key performance indicators for each process have also been established, i.e. those measures which define how well a process is performing. For example, this could be energy use per square metre of PCB produced. A list of process categories has also been established for the surface finishing manufacturing sector.

The main interactive sections of the path to energy efficiency are the tools benchmarking and energy efficiency. Separate versions of these tools are available for the two targeted industry sectors.

Benchmarking tool

The benchmark tool enables a quick check on company performance to be made. Carried out on line, the user enters general data about production and energy use. Instant feedback is then provided as to how this performance measures up against the industry standard. This is an important exercise to carry out, because it shows how a business is performing against competitors. The benchmarking tool only provides a quick check on performance, but will indicate the potential savings that can be achieved in terms of energy and cost. Strict confidentiality is applied to individual company data and only aggregated data is displayed.

Energy efficiency tool

The energy efficiency tool is a downloadable spreadsheet designed to assist companies in fully analysing their energy and cost performance (Figure 3). It goes much further than the benchmarking tool by enabling forecasts on future energy use, thus providing comparisons between business as usual and potential scenarios which could be achieve through implementation of energy saving techniques. The tool requires companies to enter detailed data to produce future energy use forecasts with the main aim of improving energy performance. It also features a calculation enabling purchase decision making on new equipment.

Figure 3 Example of an output from the energy efficiency tool

Investment decision

Energy efficiency gains are often achieved by investment in new machinery. The ultimate decision to purchase is usually based on an economical rather than an environmental case. Factors effecting this decision can include:

• •

  energy cost savings;

• •

  reduction in downtime and maintenance;

• •

  increased production rates;

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  increased operating hours;

• •

  automation of processes;

• •

  reduced waste; and

• •

  improved quality.

It is necessary to analyse all these areas to conclude whether or not an investment will add value to the company. Analysis techniques can include cash flow and net present value calculation over the expected life of the equipment. As well as the savings which can be made, there are often funds and assistance available for equipment that offers environmental improvements. This can include grants, interest-free loans and tax relief. The information accessed through the energy efficiency advisor takes the reader through the options for using external loans or own company finance. It describes the use of a third party to either lease the equipment or to use energy services companies. It also details the potential funds available in various European countries.

Energy saving opportunities

The main path describes the route to energy efficiency. Additional information is also available, which can be accessed through the signpost energy saving opportunities at the side of the path and contains the following:

• •

  Technology intelligence and roadmap. Technologies, know-how + other measures with the potential to reduce energy consumption during manufacturing.

• •

  Best practice guides. Detailed guide of surface finishing processes and related industries including advice on drag out reduction, air agitation, extending bath life, rinsing techniques and heating. Also includes general energy saving good practice, e.g. space heating and lighting.

• •

  Benchmarking methodology. A full description of how the numbers used in the benchmarking tool have been generated.

• •

  Ideal factory priorities. Goes into more detail regarding the order in which to implement energy saving practices. Also reviews regulation and personnel issues.

• •

  Life cycle assessment (LCA). It is important that energy saving measures do not result in increased environmental load from other impacts, e.g. toxicity, waste production. This study details methods of analysing typical processes using LCA techniques which consider all environmental issues.

The project is being completed by a consortium from across Europe. The partners are selected to offer the necessary mix of skills, experience, industry contacts and dissemination routes to enable production of useful tools for energy efficiency:

• •

  C-Tech Innovation Ltd, UK (Co-ordinator).

• •

  European Institute of Printed Circuits, The Netherlands.

• •

  Union des Industries de Traitement de Surfaces, France.

• •

  Protection des Métaux, France.

• •

  Env-Aqua Solutions Ltd, UK.

• •

  BESEL, S.A., Spain.

The SurfEnergy project is supported by funding from Intelligent Energy Europe.

The sole responsibility for the content of this article lies with the authors. It does not necessarily reflect the opinion of the European Communities. The European Commission is not responsible for any use that may be made of the information contained therein.