Ball

Energy

Ball used 4.6 million megawatt hours of energy in 2016, 2 percent less than in 2012. Our Global Beverage Packaging business accounted for 85 percent of the total. We increased the energy efficiency in that business (measured per unit of production) by 5 percent since 2012. By using energy more efficiently, we reduce our operating costs and our carbon footprint.
Every Ball plant commits to annual energy goals supported by detailed action plans. Real-time energy information systems provide visibility into our operations at the equipment level so we can better understand, manage, report on and benchmark the performance of energy-consuming processes. The majority of Ball plants have formal energy management systems in place and six were certified according to the ISO 50001 energy management standard at year-end 2016.

To significantly and cost effectively reduce our energy consumption, we follow a global energy strategy that addresses energy supply and demand and requires the consideration of energy efficiency when making investment decisions.

 


A MULTIFACETED APPROACH

Opposing trends, such as increases in can sizes, shapes and labels, line or plant curtailments, and new line startups, often offset progress toward our energy efficiency goals. Our efficiency decreases as manufacturing line stoppages increase due to reduced demand or we experience a greater number of height, diameter or label changes. In particular, our beverage packaging business continues to experience a decline of standard can sizes, growth of our specialty can business and shorter production runs. To manage these challenges effectively, we invest in our businesses and expect additional energy performance gains in 2017 and beyond.
Wind Turbines
Case Study: OPENING THE CAN ON RENEWABLE ENERGY IN FINDLAY

For the first time in its history, Ball entered the world of renewable energy in 2015, adding another layer to our efforts to address climate change. Our highly engaged workforce in Findlay, Ohio, teamed up with a local renewable energy service provider to harness the power of the wind.

One Energy invested $18 million to install five 1.5 megawatt hour wind turbines on land next to our Findlay metal beverage and food packaging manufacturing plant. Ball committed to a 20-year fixed electric rate for power supplied by three turbines, which will generate 13 million kilowatt hours per year, representing 20 percent of the plant’s electricity needs. With this first step to a low carbon energy supply future, we are avoiding more than 8,200 metric tons of greenhouse gas (GHG) emissions per year, equivalent to the annual emissions of 1,800 passenger vehicles.

Beyond the environmental advantages, this project drives employee engagement and benefits the local community. The project partners also established three $5,000 annual scholarships for local high school students pursuing a STEM (science, technology, engineering and math) degree in higher education.

We continue to look for additional renewable energy opportunities at all of our locations and signed the first power purchase agreement for solar energy at our Fairfield, California, plant in early 2016. The panels will produce approximately 1.8 million kilowatt hours of electricity per year.


 

COMMITTED AT ALL LEVELS

Ball’s management team is committed to energy improvements and invested $13 million in energy-saving projects in 2016. These measures will generate estimated electricity savings of 39 million kilowatt hours and natural gas savings of approximately 104 million kilowatt hours per year, exceeding the annual energy consumption of 4,500 average U.S. households.
 

LEARNING FROM OTHERS

Partnerships with external energy experts provide tools, resources and technical assistance to enhance our efforts and allow us to learn from other organizations. For example, Ball joined the U.S. Department of Energy’s “Better Buildings, Better Plants” program in 2010 to learn about energy management best practices and benchmark our operations with those of other manufacturing companies.