Reducing Energy Consumption in an Industrial Plant: Feasibility Study on the Implementation of a Building Management System (BMS). Tetra Pak Closures Italy case.

Minimising energy usage presents a significant challenge for contemporary business, as intricate production processes and supporting systems frequently result in elevated operational expenses and environmental repercussions. This thesis examines how specific management, and technological strategies might improve energy efficiency in an industrial setting, with an emphasis on the Tetra Pak Closures facility in Sezzadio, Italy. The assessment commences with a comprehensive analysis of the plant's energy profile, which includes electricity, natural gas, and on-site renewable production, and identifies key energy-intensive sectors such as compressed air systems, process chillers, and HVAC. Data-driven methodologies were employed to delineate consumption baselines, identify inefficiencies, and construct key performance indicators (KPIs). Emphasis is placed on the viability of a Building control System (BMS), intended to facilitate real-time monitoring, enhance load control, and optimise equipment functionality. Seven Energy Conservation Measures (ECMs) were proposed, including the reduction of compressed air leaks, deployment of an advanced sequencer, optimisation of chiller setpoints, and the adoption of a heat pump system. Economic assessments, including payback calculations, reveal that several actions can deliver large cost reductions within a relatively short time frame. A three-year roadmap demonstrates how coordinated strategies, including the implementation of the BMS, may diminish overall energy consumption of the plant while concurrently improving productivity and dependability. This thesis presents a replicable framework that integrates technical, managerial, and organisational insights to direct manufacturers towards enhanced sustainability practices. The results indicate that, via ongoing surveillance and deliberate, focused measures, industrial establishments can attain both financial and ecological advantages.