Case Study: Consol Glass Wadeville (FSO)

Consol Glass South Africa manufactures glass-packaging solutions for a number of industries, including beer, wine, food and spirits, as well as tableware and packaging for pharmaceutical and cosmetic products, to a range of local and international customers.

In 2013, the Industrial Energy Efficiency (IEE) Project introduced the Wadeville plant to the new industrial energy-efficiency concepts of energy-management systems (EnMS) and energy-systems optimisation (ESO). As a result, a specific fan system was identified for optimisation.

International experts guided students at the Wadeville plant in the measurement and analysis process to ensure accurate results and reliable savings-potential figures.

Consol has operations in Clayville (Midrand), Wadeville (Germiston), Nigel (Johannesburg) and Bellville (Cape Town), with a total production capacity of 950 000 tonnes of glass per annum. The company has a turnover of approximately R4,5 billion and some 1 800 employees.

For a total monetary investment of R1 948 018, Consol realised an annual financial saving of
R1 800 000 and an energy saving of 2 117 650 KWh. It also reduced GHG emissions by
1 905 tonnes of CO2 for the year. The total pay-back period was 1,2 years.

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