Adrien Villani, Plant Manager Rodange
Drastically reducing our gas consumption
Currently the top sustainability focus area at Rodange is reducing our gas intensity (our gas consumption per square meter of labeling material produced). The site has been on a gas reduction journey since 2015, but we recently started a rapid gas reduction project to add some extra momentum. “We had already made good progress, but our hope was that we could drive our consumption down even further if we involved more people in the project,” says Adrien.
We put our heads together, focusing on three key areas:
Step 1: Measure consumption. We used to monitor our consumption on a quarterly basis. Now we look at it weekly and we are developing data acquisition tools so that we can look at it daily. “If we measure our consumption every day, that means we can challenge it every day,” says Adrien.
Step 2: Maintain our equipment. We make sure everything that consumes gas is in good condition and working perfectly, such as our gas burner, the insulation, and the position of the valves.
Step 3: Maximize efficiency. We have perfected our set-up to maximize efficiency and we make sure that we do not use more energy than is needed. “We use LEAN methodology at the site, and one of its key principles is that anything you overuse - whatever goes beyond customer expectation - is just a waste,” explains Adrien.
This new approach has led to great results. We reduced our gas intensity by 14% in Q1 2023 compared to Q1 2022, and reduced it a further 4% this past quarter. Since we started this journey back in 2015, we have reduced our gas consumption by 25%, even as we increased production.
“Before we started this project, we thought we had done pretty much everything we could to consume less gas,” says Adrien. “However, getting additional focus, bringing more people in, and making sustainability a daily topic of activity helped us achieve a further 18% reduction. It’s better than we were expecting, and has motivated us to achieve even more.”
Driving further change at Rodange
Going forward, we will continue to reduce our gas intensity at the Rodange site, with the aim of achieving further significant reductions, and then transition the remaining usage over to renewable energy. We are looking for opportunities to do this in all areas of our production.
Reducing our gas intensity is just one way we are driving sustainability improvements at Rodange. When it comes to recycling, we work hard to ensure that 100% of our raw material leftovers are collected, unwound, classified, and shipped to recyclers, and we reuse the cores of our raw materials. To sort our waste - and give back to the community - we partner with GP Lux, a company which gives job opportunities to disabled people.