Implementation of an energy management system at Etria Manufacturing

How Etria Manufacturing (formerly Toshiba) reduced its energy consumption by 50% in one year.

The Etria Dieppe site achieved significant energy savings after renewing its cooling units and air compressors. Additionally, with the MyDametis platform, the teams have become more autonomous in energy management.

“We called on Dametis in 2020 to carry out a project whose aim was to reuse energy from our processes to heat buildings. In the first year, we reduced our gas consumption by 50%. The MyDametis tool gave all our staff easy access to their consumption data, which they could then analyze.”

Mohamed Mebtoul, Toner Department Manager

Etria (formerly Toshiba), Dieppe.

Watch the testimony of Mohamed Mebtoul, Director of the Toner Department at the French factory Etria Manufacturing.

RESULTS

Results in figures

-50%

in gas consumption in the services building in 2022, due to the recovery of waste heat from air compressors and chillers.

– 40 000€

of energy savings on the annual bill in 2022 thanks to early detection of deviations. The result: better control of total heat energy

– 15%

in total heat energy consumption thanks to better optimization of heating control (scheduling, etc.) via MyDametis software and its energy management system.

641 MWh

saved over 2022

146 T eqCO2

saved over 2022

CONTEXT

Etria Manufacturing, a leader in toner ink production.

A giant in the manufacturing of electronic and computer equipment, Etria also offers solutions in data storage, energy, and infrastructure.

Etria Dieppe (formerly Toshiba) is one of the two largest global toner ink production sites of the Japanese group. The site opened in 1986, and started out assembling photocopiers. In 1993, he began producing toner ink: spraying, plastic injection, bottling and cartridge assembly.

Etria Dieppe in a few figures

230

Employees on site

€30M

Turnover

Certified ISO

ISO 9001, ISO 14001, and ISO 45001

Labeled

“Showcase of the Industry of the Future”

1986

Located in Dieppe for over 35 years

The site comprises 3 buildings

Toner building

Toner manufacturing building. Includes 2 chillers for machine cooling and 7 air compressors.

Services Building

Building dedicated to the assembly of photocopiers. Includes a small compressed air station.

Logistics building

Building dedicated to finished product logistics.

CHALLENGES

Overheating cooling units and worn-out air compressors

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1st challenge
1st Solution

Overheating Chiller Units

The Toner building is dedicated to the manufacturing of toner cartridges. During the process, the machines generate a lot of heat. To prevent any risk of overheating, two chiller units condition the air and maintain the production circuit at the right temperature.

However, a problem arose: the chiller units started showing signs of fatigue, especially during heatwaves. This issue is critical for the Toshiba Dieppe site as the cold production must never be interrupted.

Installation of new
chillers

The priority was to replace the two chillers at the end of their cycle. Dametis installed two new ones to ensure and sustain cold production.

Chillers condition the air temperature by removing heat from the cooling area. Dametis recovers this heat to convert it into energy.

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2nd challenge
2nd Solution

Worn-out and energy-consuming air compressors

At the same time, air compressors also began to underperform. As a result, their energy consumption was increasingly weighing on the energy bill.

Toshiba Dieppe needed to improve energy performance by renewing its air compressors in addition to its chillers.

Installation of new
compressors

Dametis has installed two new air compressors in the Toner building.

In order to optimize energy usage, Dametis has installed a heat exchanger that recovers the waste heat produced by the air compressors and chillers. This heat is then used as an energy source to heat the Services building dedicated to photocopier assembly.

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3rd challenge
3rd Solution

Inadequate tools for energy management

As part of the signing of an Energy Performance Contract (EPC), Toshiba Dieppe had to achieve specific energy efficiency targets.

To monitor the site's energy consumption, the teams were using inadequate and impractical tools and modules. As a result, collecting, analyzing, and correlating each data point was time-consuming, tedious, and repetitive.

Energy Management
Faster and Easier

Dametis proposed to Toshiba to use its collaborative platform MyDametis. Thanks to this tool, teams can visualize real-time data related to compressed air consumption, chilled water, heating energy, and electricity consumption throughout the factory.

Centralized data, automated readings, comprehensive performance reports, intuitive interface: MyDametis simplifies teams' daily tasks, saves them valuable time, and makes them more independent in energy management.

Moreover, an alarm module triggers an alert as soon as a deviation is detected on the site. The tool notably identified an abnormal consumption level on a machine, which was then replaced.