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Greenpac Mill

Niagara County

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Greenpac lines up savings with On-site Energy Manager

Overview

Greenpac Mill is a state-of-the-art mill located in Niagara Falls, NY. Recognized for its high-tech equipment, sustainable manufacturing processes, and high-performance work organization, Greenpac manufactures lightweight linerboard made with 100% recycled fibers.

The mill has a strong commitment to sustainability, community engagement, and energy awareness and has been tracking key performance indicators (KPIs) in 10 separate categories, each with their own five-year goal.

  • Energy
  • Greenhouse Gas Emissions
  • Residual Materials
  • Water
  • Sustainable Procurement
  • Innovation
  • Financial Performance
  • Health and Safety
  • Employee Engagement
  • Community Involvement
greenpac mill

Spotlight

Company Name:
Greenpac Mill

Business Type:
Linerboard Mill

Location:
Niagara Falls

Improving On-site Efficiency

Greenpac collaborated with the New York State Energy Research and Development Authority (NYSERDA) and its utility partners on many clean energy initiatives and strives for continuous improvement despite already being a new, high-efficiency facility. In an overall effort to continue to maintain and improve site operational and energy efficiency, Greenpac participated in NYSERDA’s On-site Energy Manager (OsEM) program.

Greenpac contracted a part-time energy manager through CHA Consulting, Inc. to provide technical assistance, training, identification of opportunities, implementation of energy management strategies and projects, and verifying the results. The goal was to achieve a 5% reduction in electrical energy consumed.

Plant Electrical Intensity Graph Plant Electrical Intensity Graph

Plant Electrical Intensity

Decrease in electricity use of 5% between January 1, 2018 and January 1, 2020.

“We saw our partnerships with NYSERDA and National Grid as an opportunity to exchange ideas and develop a culture of questioning our consumption. The goal was set at a 5% reduction in energy consumption."

— Craig Eddy, Project Leader-Operations

Manufacturing a Plan

A total of 45 energy conservation projects were identified with a wide variety of types and costs, including modifications to operational setpoint adjustments, refiner shutdowns, compressed air leak repairs, lighting replacements, valve upgrades and repairs, chiller optimization, and VFDs. Several of the initial projects were identified through the NYSERDA Strategic Energy Management Program Treasure Hunt, which helped uncover many great project concepts. The OsEM helped move these projects through the capital expenditure approval process, and in some cases, to final implementation.

Progress Towards Energy Reduction Goals
Energy Source Installed Approved & Pending In Development
Quantity % of Goal Quantity % of Goal Quantity % of Goal
Electric kWh 9,281,950 87% 19,097,402 179% 6,456,626 60%

87%

of goal achieved during 12-month period

Packing Results

An overall reduction of 7.1% in average kWh/ton was attained at the end of the 12-month On-Site Energy Manager period. 

The NYSERDA On-Site Energy Manager Program

Through the OsEM Pilot Program, NYSERDA cost-shares up to 75% of the cost to hire an OsEM. OsEMs work with companies to develop and implement successful energy and productivity projects. Projects may include operation and maintenance improvements, behavioral changes, energy efficiency upgrades, process improvements, throughput and scrap reduction improvements, and cost management.

Discover how to bring energy costs, and profitability, under control with NYSERDA

Visit nyserda.ny.gov/OSEM