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Energy management

Pursuant to the provisions of Article 8 of Legislative Decree 102/2014 (Transposition of EU Directive 27/2012, obligations for Energy Efficiency), IMA S.p.A., falling within the scope of the legislation as a “Large Company”, appointed an ESCo (Energy Service Company) to carry out an Energy diagnosis at its main production sites.

In accordance with the Guidelines issued by ENEA (Italian National Agency for New Technologies, Energy and Sustainable Economic Development), all IMA plants in Italy were taken into account (not only those included in the scope of this Report, but also the production units of associates of the Parent Company IMA S.p.A. held with interests of between 25% and 50%). Based on this “clustering”, the sites requiring a specific Energy Diagnosis were identified: in this specific case, the Energy Diagnoses carried out during 2019 concerned three IMA S.p.A. production plants (Via Emilia 428-442 and Via I Maggio 14-16 in Ozzano (BO), previously submitted to this diagnosis in 2015, and that in Via Romagnoli 2-6 in Bentivoglio (BO)).

The purpose of the Energy Diagnoses is to obtain in-depth knowledge of actual energy consumption at the location, in order to identify the most effective ways to improve energy efficiency, reduce energy procurement costs, requalify the energy system and thus enhance environmental sustainability. In this regard, a number of possible ways to improve energy efficiency and reduce consumption have been identified and their application will be considered in the coming years.

These are both technical (e.g. recovery of heat from expelled air, additional insulation of buildings and the reduction of solar heating in the summer, installation of PV systems and tri-generation plants – electricity, heat and refrigeration) and operational (e.g. optimatisation of the directional use of lighting, optimisation of 60 Hz electricity generation) in nature.

Various methods have been adopted by IMA to reduce energy consumption: from the adoption of responsible behaviour by personnel (for example, company regulations recommend turning off devices at the end of the working day), to investment in efficient or low-consumption installations, machinery and devices (general and auxiliary production services), including the addition of control systems to installations in order to monitor energy use constantly (principally electricity and natural gas), with the possibility of programming their operating parameters and on/off times and obtained feedback in the event of losses and/or faults.

During 2021, IMA will implement an ISO 50001 management system at the above plants, subjected to energy diagnoses in 2019, which will be audited by third parties.

In 2020, the Italian companies of IMA purchased 69.3% of the 95,877 GJ of electricity purchased derives from renewal sources: compared with 2019, when the only locations to purchase electricity from certified renewable sources were Via Emilia 428-442 and Via I Maggio 14-16 in Ozzano (BO) for IMA S.p.A. and via Michelangelo Buonarruoti 4-6 in Segrate (MI) for Eurosicma S.p.A., the scope of application has been extended to:

– Via Nobel 28 and 32, Ozzano dell’Emilia (BO)
– Via Piave 16, Ozzano dell’Emilia (BO)
– Via Libertà 1-15, Ozzano dell’Emilia (BO)
– Via Bertella 20-26, Ozzano dell’Emilia (BO)
– Via Romagnoli 2-6, Bentivoglio (BO)
– Via Tosarelli 184, Castenaso (BO)
– Via Petrarca 34-40, Calenzano (FI)
– Via Petrarca 35-37, Calenzano (FI)
– Via Ugo Ferrandi snc, Parma (PR)
– Via Piero della Francesca 26, Trezzano sul Naviglio (MI)
– Via Tolara di Sotto 121/a, Ozzano dell’Emilia (BO)
– Via Kennedy J.F.17, Zola Predosa (BO)
– Via Parini 1, Zola Predosa (BO)

At Group level, IMA Swiftpack Ltd. site also purchases electricity from renewable sources, and together with the Italian companies IMA covers 51.4% of the electricity obtained from certified renewable sources.
In addition, the Italian PV installations generated and self-consumed 2,333 GJ of electricity, while 660 GJ produced were sold to the grid.
The most energy-intensive installations at IMA plant are used for heating and cooling (e.g. air-conditioners, refrigeration units, heat pumps), steam generation and the treatment of process waters (e.g. reverse osmosis demineralisation), lighting, UTA (air filter units), as well as forced ventilation, compressed air, powering of back-up power and emergency units, frequency converters, production and testing machines and the technological devices typically used in offices.
Over the last year, there has been an increase in the total electricity consumption by IMA Italian companies. At the same time, in line with previous years, there was a further simultaneous expansion of the number of IMA’s industrial sites, which in 2020 again marked a growth in terms of personnel and production area. Per capita energy intensity, being electricity consumption divided by the total number of IMA employees in Italy, is calculated to be 7,147.08 kWhe. The number is 6,014.64 kWhe at IMA Group level.

Considering the Italian perimeter of IMA, the consumption of natural gas, diesel and LPG is primarily due to the functioning of plants and machinery, also in the service of production (mainly for central heating systems and the production of hot water for non-industrial use). In particular, increase in natural gas consumption reflects the widening of the reporting perimeter. Energy intensity, calculated as the consumption of methane gas divided by the usable surface area of IMA in Italy, is 9.0 Smc/m2, while the number is 5.3 Smc/m2 for IMA in the world. Energy intensity, calculated as the consumption of methane gas divided by the volume of the workplaces of IMA in Italy, is 1.5 Smc/m3. The remaining fuel consumption (petrol, in addition to those mentioned above) can be attributed to refuelling of cars and trucks from the company pool. 

SUMMARY OF ANNUAL ENERGY CONSUMPTION (GJ) TOTAL 2018 TOTAL 2019 TOTAL 2020
ENERGY CONSUMPTION FROM FUELS
Natural gas (used for heating work environments) 116,323.00 110,914.50 124,950.84
Methane (used in vehicles) 1.00 21.64 4.50
LPG (used for heating work environments, roasting and testing roasting machines) 57.00 314.44 184.69
LPG (used in vehicles)   59.45 58.11
Diesel (used for heating working spaces, generators, motor-driven fire-fighting units, high-pressure cleaners) 30,945.00 37,008.23 3,381.46
Diesel (used in vehicles) 32,356.85 27,216.09
Petrol (used in vehicles) 1,322.00 6,068.41 3,793.71
TOTAL 148,648 154,386.65 159,589.40
ELECTRICITY CONSUMPTION
Electricity
129,710 128,760 129,829.13
of which from certified renewable sources 33,175.00 35,945.00 66,948.09
Self-produced and consumed electricity (from photovoltaic systems) 1,351.23 2,683.77 2,512.30
Total electricity consumption from renewable sources 34,526.23 38,628.77 69,460.40
Electricity that is self-produced and sold/fed back into the grid (by photovoltaic systems) 29.49 666.00 659.85
Self-produced electricity (from photovoltaic systems) 1,380.72 2,683.77 3,172.16
TOTAL ELECTRICITY NEED 131,061.23 131,443.77 132,341.43

 

Investments in energy efficiency and the use of renewable energy

IMA has prepared programs and initiatives for the ongoing reduction of environmental impact and to increase efficiency in the use of energy resources.

In particular, in pursuit of this commitment, IMA has implemented the following policies in Italy:

gradual expansion of the number of plants whose electricity drawn from the grid is certified as renewable by specific Guarantees of Origin (GO) issued by the distributor, until they all are;
Generation of renewable electricity by photovoltaic installations:

  • factory of IMA S.p.A. in Via Emilia 428-442, Ozzano dell’Emilia (Bologna, Italy): capacity of 155 kWp;
  • factory of IMA S.p.A. in Via Piave 16, Ozzano dell’Emilia (Bologna, Italy): capacity of 310.9 kWp;
  • factory of IMA S.p.A. in Via Nobel 34, Ozzano dell’Emilia (Bologna, Italy): capacity of 19.5 kWp;
  • factory of Ilapak Italia S.p.A., Via Lama 11-13 Foiano della Chiana (Arezzo): plant with a capacity of 55.575 kWp;
  • factory of Eurosicma S.p.A., Via Michelangelo Buonarruoti 4-6, Segrate (MI): plant with a capacity of 158.4 kWp;
  • factory of Atop S.p.A. in Barberino Tavarnelle (FI), località Valcanoro: 2 plants of 93.195 and 94.32 kWp; 

Construction has started on a new building for use by the Safe Division of IMA S.p.A. in Ozzano dell’Emilia (BO), which will have a photovoltaic system with a nominal power of 924 kWp installed on the roof;

  • a plant has recently been leased in Via degli Artigiani in Castel San Pietro Terme (Bologna, Italy), for future use by the IMA Life Division, fitted with a 999.58 kWp photovoltaic system on the roof, which comes with surface rights; all the output of this plant is sold to the grid. The new offices to be built soon will have a second PV plant on the roof, with a nominal power of 95.76 kWp for self-consumption;
  • during 2020, work continued in working environments on the replacement of fluorescent lighting with new generation LEDs; over the years to come, this is expected to take place gradually at all the plants; production of renewable thermal energy using solar collectors (supporting the thermal plant at the factory in Via Emilia 428-442), with a consequent saving in the consumption of methane;

implementation of a program, over the past few years, for the gradual replacement of:

  • old compressors with new models fitted with inverter drives that are more efficient, even under partial loans, in order optimise the production of compressed air;
  • conditioners and refrigeration units with new heat pump models, with variable levels of compression that ensure greater efficiency under partial loans and allow for the centralisation of installations;
  • traditional boilers with condensation boilers, that exploit the condensation of exhaust fumes to recover calories usable to heat water, thus delivering the same amount of heat while consuming less natural gas;  
  • UPS (gruppi di continuità) con nuovi modelli più efficienti.