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Resource and Energy Efficient Manufacturing

Final Report Summary - REEMAIN (Resource and Energy Efficient Manufacturing)

Executive Summary:
Resource and Energy Efficient ManufacturINg (REEMAIN) combines cutting edge knowledge and experience from production processes, professional energy simulation software tools, energy and resource planning standards, and renewable energy and storage technologies to develop and demonstrate an integrated approach, methodology and platform for the boost, at factory level, of efficiency of both energy and material resources.
Based on the knowledge of who are the energy consumers in manufacturing, REEMAIN project offers four solutions. 1) Integration of renewable energy resources within the overall factory environment, taking into account innovative technologies for better use renewables with the aim to reduce overall energy demand and lead the drive towards net zero carbon factories. 2) Optimisation of the production processes and techniques, and ensuring minimum demand of energy supply and material resources through predictive simulation models. 3) Factory level energy and resource planning decision support tools to help decision makers and factory managers make informed decisions with respect to where best invest their limited financial resources. 4) Sustainability assessment, considering the environmental impact minimisation of the incorporated improvement actions.
REEMAIN as a demonstration, aimed to test the selected efficiency solutions in three different and complementary factory environments. Demonstration activities took place in three different strategic European factories: Bossa textiles, Gullon biscuits and SCM foundry. Through these factories, REEMAIN demonstrated and made possible replication to the important EU textile, food and steel production industries, which account for more than 50% of CO2 emissions and more than 20% consumption of electricity in industry. In addition to these factories, REEMAIN had the Fraunhofer IWU “Research Factory”. This large-scale laboratory is a new building dedicated to the integration of factory energy flows, production processes, and the surrounding environment, with the aim of achieving a zero-carbon factory example for Europe.
As important as the technical work is the ability to bring it to the market at large to achieve meaningful impact across Europe. For this, REEMAIN pursued three high impact exploitation avenues. 1) Link to existing Standards and eco-factory labelling concepts through the creation of CEN workshops and participation in CEN technical committees where appropriate. 2) Leading an “MTP project extension” called iProSPER in the Intelligent Manufacturing Systems program that provided international outreach and the exchange of information to the USA, Korea, and Mexico. 3) We communicated REEMAIN project results to target audiences in the relevant industry sectors maximizing the impact beyond the project scope.
Within this framework, REEMAIN then moves toward zero carbon manufacturing and Energy Efficiency 2.0 through the intelligent employment of renewable energy technologies and resource saving strategies that consider energy purchase, generation, conversion, distribution, utilization, control, storage, re-use in a holistic and integrated way.

Project Context and Objectives:
The socio-economic situation in 2012 called for a more sustainable use of resources. By 2020, EU greenhouse gas emissions must be reduced by 20% and the use of renewable energy must be increased by 20%, compared to 1990 levels. This was especially important for the Industry sector then and continues today, which is responsible for nearly 25% of final energy consumption in Europe (one quarter constituted by electricity) and 40% of total energy-related CO2 emissions . Industry still has to tackle the challenge of a more efficient use of material and energy resources, while at the same time maintaining productivity.
Currently, the European market, with 500 million consumers, 220 million workers and 20 million entrepreneurs, is a key instrument in achieving a competitive industrial Europe. Manufacturing itself accounts for 75% of exports. In terms of job creation capacity, one out of four jobs in the private sector in the European Union is in manufacturing industry, and at least another one out of four is in associated services that depend on industry as a supplier or as a client. Additionally, SMEs make up some 2/3 of industry’s employment. Within the private sector, 80% of research and development efforts are undertaken in industry – it is a driver of innovation and a provider of solutions to the challenges our societies are confronted with .
Industry is therefore at centre stage of the new growth model for the EU economy as was outlined in the Europe 2020 Strategy .
REEMAIN demonstration factories represent three important sectors of the European manufacturing industry (food, textile and iron & steel-energy intensive)3. The EU Agro-Food Industry is highly competitive and represents 2% of Europe’s GDP and 13.5% of total manufacturing employment. The EU textile, clothing and leather industry has undergone structural changes over the last 20 years. Technological developments, combined with traditional strengths in design and quality also find their way into large consumer markets beyond the sector, such as outdoor sportswear; luxury products, and footwear. Europe also needs to improve its international competitiveness by being able to speed up transition to a low-carbon and resource-efficient economy in the energy-intensive industries such as steel, non-ferrous metals, paper, and the chemicals industry.
Based on the opportunities and barriers for achieving previous ambitious objectives REEMAIN proposed a set of technical solutions based on the analysis of the energy consumers in most manufacturing process (mechanical energy, electrical drives, and process heating and cooling):
• Innovation in technologies for better use of renewable resources and energy storage. Enabling a seamless integration in the factory processes.
• Predictive simulation models for production processes. Using these, we can focus optimization efforts, ensure minimum demand of energy and material resources, and develop better more efficient production techniques.
• Factory level energy and resource planning tools. Using these and coming from advances in the building energy simulation space, plant managers and decision makers will have for the first time complete and customizable information on their energy flows, carbon footprint, and how they relate to production processes, plant scheduling, energy sourcing options, tariff structures, and energy contract types. With these tools they will be able to make informed decisions about where best invest their limited financial resources.
• Sustainability. Assessing each technological improvement to ensure its better environmental performance.
To realize these solutions, REEMAIN:
a) Began with top down decision-making process.
b) Developed technological solutions making use of a Research Factory as a research laboratory as a previous step to the following three points.
c) Three excellent industrial demonstrations.
d) Implemented an environmental management control system.
e) Evaluated the reduction of Life Cycle costs of factories.
The aim of REEMAIN project was, based on a holistic methodology for achieving a breakthrough to zero carbon and environmentally neutral factories, to demonstrate in real manufacturing scenarios that it is possible to evolve towards these targets while maintaining productivity and decreasing product life cycle costs by 20%. Four pillars supported this general objective:

1. Innovation in the main areas needed to boost the efficient use of resources (energy and materials) at the factory: optimization of the production-process-product (PR3), seamless integration of renewable energy systems (RES), the recovery of wasted energy (REC) and measurement of the environmental improvement with a life cycle approach.
2. Creation of a decision making tool to support factory owners in the complex task of analysis, decision and planning the best strategies to drive their factories towards resource efficiency and minimal impact.
3. Demonstration activities in three different factories to validate and promote the material and energy efficiency taken measures.
4. Dissemination at European and International level together with a strong support for standardization activities.

Project Results:
For the description of the main scientific and technical outcomes of the project, we are going to follow the work packages structure of the project to make it easier to structure the information.

Wp1 - diagnosis of energy and material efficiency at factory level
The main objective of this WP was to analyse the baseline of the manufacturing environment, in the management and optimization of energy and material resources, and define the factory typologies based on different features (heating and/or cooling needs, age, energy intensity, climate, etc.).
The scope of the analysis carried out was targeted towards the sectors that the three factory demonstration sites represent: food industry, textile and Iron& Steel. That way, the extrapolation process that was be done in WP5 was more realistic than trying to extrapolate the results of demonstration to the manufacturing sector in general. Bellow the summary of S&T results:

• Analysis of the manufacturing sectors relevant to REEMAIN (biscuit, textile and foundry) with a special focus in the use of energy and resources, the potential integration of innovative energy and manufacturing technologies and the applicable standards.
• Environmental impact assessment of the three-factory demo sites prior to the later deployment of efficiency measures.

Figure 1 estimation of environmental impact of ingredients in biscuit manufacturing
• Creation of reference scenarios methodology as a basis for later extrapolation of demonstration results in each of the three factories.
• Creation of the Manufacturing Reference Scenario score (MRS score) as a way to summarize the efficiency of a factory according to the REEMAIN concept of global efficiency.
• Renewability parameter score as a parameter used for the calculation of MRS score that summarized the renewable energy source potential of a location (mainly in solar and wind energy availability)

Figure 2 Generation procedure of manufacturing reference scenario score

Wp2 - definition of performance indicators and assessment procedures
Starting from the information gathered in WP1, the first step regarded the definition of the Key Performance Indicators allowing the characterization of the factory from the 1) materials and energy use, 2) environmental and 3) process cost point of view. Furthermore, a suitable monitoring architecture was developed to guarantee the tracking of materials and energy flows through the plants to provide the necessary data flow to the virtual decision support tool (WP3), towards the optimum management of the developed solutions. Bellow the summary of S&T results:
• Definition of the relevant KPIs including a selection in each factory of the KPIs more directly related with REEMAIN main objectives (resource and energy efficiency). Assessment of the KPIs (definition and its format) with the existing classification and current standards (ISO 22400).

Figure 3 INGREDIENTS USED FOR THE KPI ANALYSIS DONE IN WP2

• Establishment of a preliminary generic data acquisition network topology to comply with the defined KPIs and the project objectives. Analysis of the demo factories existing data networks to assess any gaps in their current status.
• Definition of data acquisition architecture and interfaces for virtual decision support tool. It included a general discussion about acquisition systems in industry, the specifics of the IES simulation tool interface and the current architecture of Fraunhofer IWU’s architecture for their E3 factory.
• Systematic analysis of the developed distributed monitoring networks for the three demo cases in their respective efficiency demonstration measures. The Demo factories were asked to provide also their current situation and planning of possible expansions (for both metering and data management).
• Methods for post processing of data coming from efficiency measures, including also the exploration of data reduction procedures for a more efficient evaluation of efficiency measures. A focus on the bin method analysis was presented.

Figure 4. Energy and material flow for the efficiency measure EM1 at SCM.

• The procedures for analysing and sharing results, a suitable procedure for data analysis and KPIs calculation was also elaborated. The dynamic behaviour of the processes was explicitly taken into account. Indeed, the considered machines in the demo factories worked under different operating conditions. In order to get a detailed understanding of the effects at play, it was hence important to correlate the performance with the different operating cases. In practice, this was largely based on the bin method analysis (BMA), where data are filtered and grouped depending on the value of proper driving parameters. In order to get an overall perspective on the efficiency measure behaviour, general averages were also provided, but only on the basis of a significant number of data and in the light of the dynamic analysis mentioned above.

Figure 5. Bin method applied to the performance analysis of the dry cooler. A comparison between experimental data and nominal performance is shown.

Wp3 - technical solutions and tools for efficient manufacturing
Main objectives on this WP were an assessment/development of technological solutions and to develop a virtual decision support platform to assess product-process-production (PR3), energy recovery technologies (REC) and support RES integration in a factory. Bellow the summary of S&T results:
• A technology roadmap of innovative RES, storage and waste recovery technologies for efficient manufacturing has been developed by means of a SWOT analysis and a ranking methodology.

Figure 6 - Total scores of technology ranking for generation clusters.


Figure 7 - Screen shot of the excel survey tool used for the technology analysis


Figure 8 - Total/sub-score comparison of solar concentrator technology ranking

• Development of the rough-cut methodology (D3.3) to make an accurate estimation of energy use inside a factory from aggregated and coarse level data (e.g. gas and electricity bills). Starting from this aggregated data and information on technical characteristics of the machinery (e.g. installed power in kW) and working profiles it is possible to assign % of the total energy spent to the different levels of the factory (departments, working zones, equipment, production lines etc.). The rough-cut approach was applied to Biscuit factory where no detailed metered data at process level were available, allowing for estimation of the potential impact of some efficiency measures.

Figure 9 Comparison between rough-cut modelling and detailed simulation

• Definition of the requirements for the modelling platform simulating effectively the manufacturing processes and be able to virtually test different energy solutions and renewable. A data driven approach has been defined, which starts from metered data from the factory or from rough-cut profiles when data are not available to derive a picture of the energy use across the factory. The introduction of renewables or the implementation of energy efficiency measures were then simulated starting from these historical data and results are visualised through visual mechanisms.

Figure 10 - Overview of the approach followed by the REEMAIN simulation tool.

• Development of simulation platform optimization strategies: final integration of the final four selected REEMAIN technologies (Combined Heat, Power and Cooling, Solar Colling, Organic Rankine Cycle and Electric Energy Storage) in the VE software as part of the REEMAIN static modelling platform, Automated Demand Response, Heat recovery and Tariff Analysis.
• Simulation platform - Automated integration of the KPI’s: real-time data acquisition links with the sites, Sankey diagrams feature and cost analysis integration to create the REEMAIN Decision Support Tool.
• Automated Decision Support Tool: final decision support tool interface developments, tactic automation and workflows to carry to develop the final REEMAIN platform prototype for M36. No “real-time” live data connection with the sites were not implemented, but available data sets and information provided from each of the demos were used as possible.

Apart from the development of the new generation of manufacturing simulation tools WP3 was also devoted to two key technologies needed for the objective of seamless integration of renewables into manufacturing environments:
• Battery pack: Development and final testing of battery Management System (BMS) and PowerBox. Thermal test of the prototype with its final external envelope. The tests were done in a climatic chamber at extreme climatic conditions (-20ºC+45\C) to check if battery cells keep working on the range of 25°C and 35°C and validate the proposed thermal design. A feasibility study was also carried out taking into account Spanish and Germany markets.
• Solar Thermal Concentrator: a) further absorber tube tests (i.e tubes without glass cover were tested and results were analysed, evaluated and compared with the previous test done in period 1 of the project b), challenges resolution (i.e. irregular flow in one of the tested absorber lines) , c) final PLC enhancement (i.e resolution of working issues, improvements in the graphical user interface)

WP4 - Towards zero-carbon/neutral manufacturing
This WP developed the scientific and technical methodology that ensure seamless implementation of energy efficiency measures and technologies while considering the efficient use of resources, i.e. material, personnel, machine capacities, and corresponding technologies within the factory. The resulting methodology for planning and controlling the technologies aimed for minimal emission and cost-effectiveness within the factory with respect to external as well as internal, ecological and economical influences. Bellow the summary of S&T results:
• Development of the resource networks concept to be used at the factory level so it is possible to integrate the production processes, resource consumption and the available energy.
• Development of the Resource Networks Planning Methodology (RNPM) used for designing Resource Networks in a factory. Through its use, a complex production system can be divided into virtual subsystems: Resource Networks. Thus, a large problem concerning the design or the production planning and control (PPC) strategy of a factory can be solved more easily and in a decentralised fashion, effectively allowing easy integration of renewable energy sources.

• Development of the Linkage Methodology of Resources for defining the control strategy of a production system designed using the RNPM. This comprises a general control approach (depicted in Figure 14) and a procedural model for the development of the control logic within the RNPM (step 7, cf. Figure 13). It details the necessary inputs and concepts required for devising the control logic for the respective levels of individual Resource Networks .

• Implementation of a hybrid experiment platform in the E³-Research Factory for use in the validation process of the Resource Networks Methodology (RNM). It consists of a model for the discrete-event simulation software Plant Simulation that utilizes real measured data from Fraunhofer IWU’s E³-Resarch Factory and actual processes to allow for the investigation of production control strategies of a (virtual) SME toll manufacturer. Different control strategies, e.g. for different Resource Networks designs, can be implemented and investigated regarding logistic- and energy-related performance indicators.

• Development of a simulation model of the E³-Research Factory using Siemens Plant Simulation that was used for the validation of the Resource Networks Methodology (RNM).
• Development of a procedure model for the efficient application of integrated simulation of material and energy flows to be used in the validation of production control strategies developed with the RNM.
• Development of a concept for a mobile app to assist the application of the RNM.


• Application of the Manufacturing Reference Scenarios (MRS) methodology to the automotive sector using the E³-Research Factory as an example. Therefore, a detailed MRS analysis was done. First, the MRS Renewability Module was used for an European location comparison including weather conditions and energy prices. Furthermore, the MRS Company Module was used with data from companies of the Automotive sector. Two sample products and processes of the E³-Research Factory (forming of pinions and producing of gear-tooths) with respective energy demands and specific weights were compared to the data of the Automotive sector aiming at finding potentials for improving efficiency and energy consumption per product. This analysis was focused on electricity consumption.


• The objective of the Development of the REEMAIN methodology was to synthesize the information from various deliverables in light of the study of methods for mapping factory flows. The resulting document is a set of practical steps which factory management can take to improve its resource efficiency. It also incorporated examples of exergy analysis of selected efficiency measures at the demonstrator sites. REEMAIN methodology is the basis for the related standardization activity done in WP7 as a CWA or consortium workshop agreement.

Wp5 - Demonstration in selected manufacturing scenarios and concept extrapolation
The objective was to demonstrate that the innovative tools and technical solutions for resource efficiency and developed methodology were successfully applied to the selected demonstration factories (biscuit, textile and foundry) and met the foreseen targets. In addition to the validation itself, an extrapolation of results to the spectrum of manufacturing scenarios, that the three demonstration sites represent, was also done. See results of this WP bellow:
• Analysis of the three-factory demo sites to assess their status in energy and resources use with the objective of create a full list of potential energy and resourece efficiency measures. The full list was later filtered so the more innovative and achievable demonstration features are selected and agreed so the next commissioning phase is started.


Figure 18 Virtual models of the three REEMAIN demo factories

• The starting point for the work was the list of the selected EMs. An already filtered set of possible efficiency measures was set and then, demo factories refined the first list of possible efficiency measures and selected the final winners to be deployed. Final decision was taken by each factory manager after meetings with their maintenance/machinery suppliers and staff, and also “some listening“ to the advise of the different factory clusters members. For the selection it was used a multi-criteria approach based on relevant parameters like: extrapolation to other factories and sectors, innovation level, impact at the factory itself, return on investment and technical feasibility. The final list of preliminary selected efficiency measures to be installed in each of the three factories is shown:

• The final list of efficiency measures tested in the three factories is shown in the picture bellow and grouped according the project objectives (Heat recovery, optimization of production-product-process and integration of renewables)

Regarding to the main results obtained in the EMs of the three factory demos, the main ideas and results are summarized below per each factory:
Efficiency measures for the GULLON biscuit factory demo:
• EM1 Oven Heat Recovery
The heat recovery system in the biscuit ovens was achieved through the of upgrading existing old oven of sample manufacturing line, with the corresponding heat exchangers. Before the oven upgrading, a measuring campaign was taken in the old manufacturing line. Once installed and commissioned the upgraded oven, the natural gas savings found were about 70% which is a spectacular result. However this comparison was not quite fair since the old oven was a 20 years old oven. Additional measures allowed the comparison of the new oven equipped with heat recovery mechanisms versus another new –5 years old- oven when both ovens were manufacturing the same biscuit reference. In this fairer scenario, the natural gas savings are still an awesome value of 40% in terms of natural gas consumption per kilo of baked biscuits.

• EM2 Precooling of the G4 Cold Generation System
In this renewable energy measure, the installation of an external dry cooler on the factory roof has been implemented to work in a coordinated way with the existing 2.4 megawatts thermal power electric chillers based system. The existing systems provides cold water at 5ºC to factory cooling tunnels and get it back at 10ºC. Taking advantage of the available low external temperatures, the new heat exchanger is capable of providing sensible cooling with much higher energy efficiency than classical electric compressor chillers. The design objective of this measure was the use of partial free cooling air-water. This is, under the presence of the required external low temperatures, the return water flow would be partially cooled and later the electric chillers would achieve the final temperature reduction. The monitoring campaigns have showed reduced periods of time where the new dry cooler was capable alone to provide the required chilling effect. The yearly savings obtained are of around 235.000 kWh, that equals 12% of annual electricity consumption of the original G4 cold generation system. Although the temporal distribution of these savings is not constant throughout the year. Logically, electricity saving is practically null during the summer, while reaching its peak of 59% during the month of January.


• EM3 Unification Of Hot Water Generation System
In this measure three separated hot water circuits equipped each one with a specific natural gas boiler have been unified in a common manifold and connected to a new high level control system responsible of the coordinated operation of the three boilers depending on the factory demand. The three hot water circuits came originally from historical enlargements of the factory. And also, as usually happens, the corresponding boilers were highly oversized in the original design. So the starting point was three separated circuits that all of them were operating in very low partial load most of the time except some reduced periods of time –hours- during the coldest winter Mondays. The unification of the boilers has replaced the constant cycling operation of the three boilers with a new situation where only two –and sometimes even one- boilers are capable of providing the required thermal demand with a higher value of boiler partial load and therefore a higher efficiency in terms of natural gas consumption. Some leakage problems have prevented to work continuously with the three boilers fully unified. However, even with this handicap, the savings obtained through direct measure of natural gas consumption and thermal energy production show an approximated value of 15%. This measure has already been replicated in the other factory of Gullon.

• EM4 New Efficient Free Cooling Control
This EM is the optimization of the software controller of three Air Handling Units, AHU responsible of the air conditioning of three processing rooms in the Gullón factory. In a classical enthalpy free cooling controller, under the presence of the required outside air with lowest enthalpy values than the room air, the introduction of external cold outside air is used a free way to achieve the required room air chilling. However, in rooms where there are strict limits for the allowed relative humidity, the introduction of dry cold outside air might require –or not- the later use of the electric humidifier –adiabatic humidifiers are not allowed in food factories-. This intensive humidifier use might require more energy consumption than using the electric chiller and recirculating the room air, this is, than not using the free cooling strategy. Under the possibility of free cooling use, the new PLC software developed for this measure periodically simulates thermodynamically the global cost –including chillers and humidifiers- of both options and decides which of both strategies would produce the lowest electricity consumption. The monitoring campaign provided an average savings for the three rooms between 4% and 6% against a classical enthalpy free cooling controller. One unexpected result is the high variability in the savings of the three rooms. Under the same external conditions –same weather profile- small variations in the inside room temperature and humidity set points produce large variations in the obtained energy savings.

• EM5 Energy SCADA
In this EM the main energetic variables have been monitored and visualized in a new SCADA system. Because the Gullón factory was built through successive enlargements and the continuous incorporation of new production lines, there is a big lack of energy consumption monitoring devices. Besides nominal values and some spot monitoring points –and not connected to any recording system, there are not metering devices along the different production machineries or the auxiliary services. In this measure, the specific energy consumption of the mixing, forming, baking and packaging stages of line 16 have been measured and recorded. Additionally, it has also monitored the electricity consumption in the main electric transformers rooms, the air compressors system and electric chillers system. Thanks to this new energy SCADA the specific consumption of each machine or system can be easily and intuitively visualized as long as the system provides the corresponding warnings in case of abnormal energy consumption. All the monitored variables are also been recorded in a central database for future data analysis. A similar system is also being implemented in the other factory of the Gullón company. As a “soft” measure the savings are difficult to estimate but best-practices in many sectors ensure that energy-awareness monitoring programs can generate up to 25% of energy reduction.
Efficiency measures for the SCM Foundry demo:
• EM1 – Flue gas pilot heat exchanger:
This pilot heat exchanger aims at investigating the feasibility of heat recovery from the flue gases of the cupola furnace. A first measurement campaign was carried out during 2015 with a heat pipe heat exchanger (HPHE) installed upstream of the cyclones, at high temperature (order of 600 °C). This led to the explosion of the HPHE after a couple of weeks, possibly due to a combination of design limits and operational issues on the secondary water circuit. A second campaign started in May 2016, with a system of identical design. This second installation was performed downstream of the cyclones, where the lower temperature (order of 400 °C) and lower dust content is expected to allow easier operation. One full year of data is reported in this document. The same data were used, in close contact with SGR and the Municipality of Rimini, in order to design a full power heat exchanger to provide hot water to a near external district heating; unfortunately, this is not economically feasible yet and so not commissioned.

• EM2 – Refurbishment of the compressed air system: installed and running.
This EM consisted of two activities: the refurbishment of the distribution pipes and the substitution of one of the compressors, replacing an old fixed speed compressor with a variable speed drive (VSD) one. Data concerning the new system start from the beginning of 2016; they are compared with the data of 2015 to assess the performance improvement deriving from this EM. A significant reduction of electricity consumptions (order of 15 %) for the compressed air system could already be assessed, though a slight worsening has been experienced in the last year probably due to scheduled need of servicing.

• EM3 – Heat recovery from air compressors: installed and running.
This measure aims at recovering the heat wasted from the compressors in order to heat the coreshop and the patternshop of the factory. A minor part of the heat will also be used for sanitary hot water production, in series with an existing boiler. EM3 started in late November 2016 and stopped in April 2017, due to the end of the cold season. Data collected in this period are reported hereafter.

• EM4 – Air destratificators: installed and running.
This measure aims at improving the temperature distribution within one of the departments of the factory. The situation for this measure is similar to that of EM3 and strictly connected to it, hence date here reported come from the same source.

• EM5 – Plasmapour: installed and running.
This EM is expected to significantly improve the operation of the casting process, with positive effects on the holding furnace (electric induction Fomet oven), the production line A (where the system will actually be installed) and the production line H (which will indirectly benefit of the more stable operation of the holding furnace). This system was installed during the summer break of 2016 and started on September of the same year. At the moment of the writing Plasmapour is still working normally so that one full year of data coming from this EM is available and reported hereafter.
Efficiency measures for the BOSSA Denim Fabric factory demo:
• EM1 - Improvement of Machine Speeds for Spinning and Weaving:
BOSSA Denim Factory Spinning and Weaving departments contain machines with high speed motors. When you increase the motor, speed energy consumption increases, however the amount of extra energy spend is expected to be low compared to the gain of extra production. It is planned to increase motor speed to increase production rate hence it is expected to achieve reduction of energy consumption per meter. Hence, this fact is used to try to minimize the energy per unit production quantity by controlled increase of the machine speed. The speed was increased up to the limit of safe and high quality production. Experiments were designed to test this limit together with Quality Control Department. Production team collaborated with Quality Control team in designing and performing these experiments. The measure for quality as a function of machine speed was obtained. Then the new speed was compared to old speed, and the specific energy consumptions were computed. This efficiency measure was easy to implement but resulted in low energy savings than expected. Yearly savings for Bossa was around 20K €/year. Investment was very low but the results were not as good as calculated earlier. This measure can be expanded to all spinning machines.

• EM2 - Decreasing Process Duration and Number of Steps in Dyeing&Finishing:
Dyeing & Finishing department has a share of over 80% in total water and natural gas consumption. Thus this efficiency measure was designed to decrease consumption for this department. The measure was finally defined as to reduce the water consumption for Dimensa Mercerizing machine where raw washing, prewashing & mercerizing as well as mercerizing processes take place.
The amount of hot water consumption decreased as a result of the experiments of this measure. Energy conservation resulted due to conservation of hot water.
This efficiency measure was relatively easy to implement. It was also found with very high return on investment since investment was only on data acquisition equipment. Bossa gained around 100K €/year due to implementation of this measure. There are too many washing processes in industry where this measure can be applied effectively without loss of quality. Hence we found this measure as the most replicable one among all BOSSA efficiency measures.

• EM3 - Development of Environmentally Friendly Fabrics:
Expectations of customers and end users related to their environmental consciousness force textile industry to find innovation solutions and environmental approach to their products. Based on this, one recycled, one organic and one naturally dyed denim fabrics were developed. This efficiency measure is applied by mainly Product Development and Product Management departments.

• EM4 - CO2 Waste Water Treatment:
BOSSA used carbonic acid instead of sulphuric acid in their new constructed waste water pool. The new pool had to be constructed for this efficiency measure to be successful. The return on investment is high, amount of savings is found to be 235K €/year. Due to special pH value of their waste water and the pool requirements the replicability of the measure is lower than other measures. Environmental consequences of this measure is also important since release of sulphiric acid is replaced by less harmful CO2.

• EM5 - Waste Heat Recovery System:
In textile industry washing machines are commonly used at the finishing processes of the fabrics.
This efficiency measure is applied on Benninger Washing Machine. The washing water used in the machine is drained when it is polluted, and fresh cold water is taken in. Drained water is around 85 °C when the process water temperature is 95 °C. So there is unused thermal energy which is lost to the drain. The aim of this measure is to keep the mentioned lost energy within the system and to reduce energy cost by means of less energy usage for heating of the washing water up to process temperature.
Washing water is heated with saturated steam. The saturated steam is obtained by burning natural gas in steam boilers. Natural gas consumption will decrease if the potential thermal energy of the drained water is used for heating instead of saturated steam. Application of this measure has decreased the amount of natural gas burned in steam boilers. As a result lower carbon foot print for the environment has been obtained as envisioned by the REEMAIN project.
This is an effective measure with significant amount of savings for Bossa. Yearly savings around 80K €/year was obtained in Benninger machine and measure was extended to a second machine where similar savings has been obtained. However, there is a need for a heat transfer system and self cleaning filter for the measure to be effective. Due to potential complications of the self cleaning filter this measure replicability may be restricted for some other industries like food and beverages industry.
After the final evaluation of the efficiency measures, the savings of each of them were compared against the baseline consumption figures, and the total savings were also computed as shown in the figures bellow.


Potential Impact:
Following the results related with exploitation and dissemination will be shown trough the corresponding WPs.

WP6 – Exploitation and market deployment
The intent of WP6 was to conduct activities that accelerated the post-project market uptake and consortium exploitation of project results in a structured and synchronised way during the project so that all available opportunities were identified, planned for, and executed. WP6 worked closely with all project work packages in the identification and treatment of exploitable results recognising also results associated with the interdependencies and assembly of the work program. See results of this WP bellow:
The initial identification of exploitable results was conducted early in the project and documented in deliverable D6.1 “Exploitable results table”. This report and table of exploitable results provided the motivation, how to, and initial clustering of ERs to include the main defining parameters of an exploitable result:
• Type: whether it is a product, a process, knowledge & IP or a service
• Innovation level: from no apparently innovative to a full new idea, pilot or prototype-
• The TRL level transition because of REEMAIN activities
• The responsible partner for its exploitation
• The reason to consider it innovative or exploitable.
• The final vision of its exploitation result.

An additional result was the receipt of the “First Synthesis Report” for REEMAIN Exploitation Planning resultant of preparation for an exploitation strategy seminar (ESS) hold immediately prior to the project first review meeting.
• Selection of 4 key exploitable results to further explore they evolution: simulation and modelling tool, battery pack, solar concentrator and engineering consultancy services.
• Market Analysis for the key exploitable results (KERs). It started with definition and sharing of the Gathering Template, sent to the KERs managers to collect information about the KERs. The market analysis was focused on value propositions, the market applications, the economic relevance, possible barriers, stakeholders and other relevant characteristics for the go-to-market step.
• External consulting from De Tullio & Partners Studio regarding IPR assistance and patenting service linked with ESIC project. The focus was on two specific results related to the technology under development by BOSSA and a specific a guideline and documents of an IP application for the IES software.
• Replication plan to define specific business model for each KERs through the canvas business model. Information about the product value, the current business model used by the project partners to sell products and services and to investigate weakness and strength points into the market was analysed. Alternative ways of exploitation were also evaluated.
• For Branding and market awareness, the project was presented at the ECOMONDO fair trade (2015). REEMAIN was also presented at the INDTCH conference held in Amsterdam from the 22nd to the 24th of June.
• In the month of April (M43) was organized by CRIT an event called “The optimization of industrial energy consumption” where the REEMAIN project was presented in a context of Italian and regional tender for energy efficiency for industrial sectors. This activity of exploitation linked with dissemination had seen the collaboration with important Italian companies and was also published thought the project dissemination channels and an Italian web TV (http://www.4industry.tv/).
• Final replication planned for each exploitable result was developed. See section 4.2 on use and exploitation of foreground for the details behind each project’s exploitable result.

Wp7 - Dissemination and standardization
The objectives of WP7 were to guarantee the professional and public coverage of the REEMAIN project results and achievements and support optimal conditions and solutions for market deployment and large-scale replication as well as the project standardisation activities.
A multi-channel approach that identifies the scientific and industrial communities as primary targets was developed and implemented. See the main achievements in dissemination:

• First version of Dissemination and Communication plan (D7.1) and successive updates in January 2015, with clear and measurable targets as well as with a main message to address the professional audiences and guidelines to carry out dissemination activities.
• Website of the project (www.reemain.eu) with an accumulated quantity of 11.136 visits, of which 8.430 unique visitors over 11 months since the launch of the website. The website has reached an aggregated figure of 10.000 page viewed and almost 2.400 users since its opening. 64% of users are new visitors.
• A community of 321 members worldwide has been established: 140 people registered to REEMAIN website and 156 member of the LinkedIn group
• 2 publications of 6-monthly newsletters covering stories outside and inside the consortia.
• Development of database of interested stakeholders (more than 240 members).

Following, a detailed view on dissemination materials, public web communication, international outreach, best practice book and standardization activities is shown.

Dissemination materials :
o 4 posters on specific topics with brief and detailed descriptions of products and processes used in the project and highlights on main results achieved
▪ Best Practices Book poster
▪ REEMAIN platform
▪ Battery-based energy solar system
▪ Parabolic Trough Collector

o 2 eNewsletters released in October 2016 and in September 2017 to update the community on new achievements, articles and events linked to the topics of the project

Best practice Book : The Best Practice Book is a brief publication for sharing REEMAIN experience with other professionals in the material and energy efficiency domain. The BPB illustrates the experiences from the three factories in Spain, Italy and Turkey that have been testing novel solutions to show how it is possible to cut energy bills and use fewer resources while maintaining productivity. Performed in the food, foundry and textile industries, the experiments are now set to be up-scaled in the same fields. The Book is made up of 18 Best Practices for future developments of energy efficiency at factory level useful for those industrial players, SMEs research organisation, public institutions and local administrations who need a guidance to improve their energy processes.


Public web communication:
• Over the project, a total amount of 73 articles, interviews, short news and press releases has been produced and published on the project website
• The amount of total impressions exceeded 1500 on social media and 8.500 on multipliers. Articles were mentioned more than 200 times and the total outreach, originated mainly by twitter activity, reached 557.782 impressions.
• The accessible data show that press releases and short articles were visited 262 times, 236 by unique visitors.

REEMAIN international outreach:
The iProsper project in collaboration with US research institutions had already been created in the first phase of the project. In the second period, collaboration intensified with the LMAS (Laboratory for Manufacturing and Sustainability of Berkeley University) for possible projects of common interest with REEMAIN.

Support to standardization activities:
UNE, as member of the project REEMAIN, and the Spanish standardization body, is in charge of the standardization tasks, in particular, T7.8 Support to Standardization activities. Related with these activities, under this task three deliverables were made. The first deliverable is D7.7 Roadmap to progress the standardization activity, to show the partners the steps to standardize the results of the project identified in its chapter 3. Once this document was delivered, first actions have been followed in order to progress in the standardization as they were stablished in chapter 4.
The second one was D7.8 Report on the preparatory steps taken to progress the standardization activity, where it was reported the preparatory steps taken to progress in the standardization activity. It contained the steps undertaken up to its delivery, and the further ones expected.
Finally in deliverable D7.9 Report on the progress of the standardization activity, was showed the progress of the standardization activity as was designed in D7.7 and, later on, started as reported in D7.8.

The final standardization activities have been:

1. Resource and Energy Efficiency manufacturing REEMAIN Methodology
2. Lithium–ion battery-pack design and development
3. Solar thermal concentration technology

List of Websites:
Following, the main contact details of the different partners involved are presented:
Project Coordinator:
Anibal Reñones (Deputy Head of unit of the Engineering Systems Division)
e-mail: aniren@cartif.es
Centro Tecnológico CARTIF
Parque Tecnológico de Boecillo, 205. C.P. 47151
Boecillo, Valladolid. España
Tel. 983 54 65 04 Fax 983 54 65 21
Project Dissemination & Communication Secretariat
Elena Gaboardi
e-mail: secretariat@reemain.eu
Name Email Organization
Anibal Reñones aniren@cartif.es
1- Cartif
Francisco Morentin framor@cartif.es
1- Cartif
Ainhoa Gonzalez aingon@cartif.es 1- Cartif
Vincent Murray vincent.murray@iesve.com
2- IES
Catherine Conaghan catherine.conaghan@iesve.com 2- IES
Rick Greenough rgreenough@dmu.ac.uk
3-DMU
Carlos Zaballos czaballos@gullon.es
4-Gullon
Mustafa Deniz MDeniz@bossa.com.tr 5-Bossa
Ozgur Demirel odemirel@bossa.com.tr 5-Bossa
Roberto Fedrizzi roberto.fedrizzi@eurac.edu
6-EURAC
Marco Cozzini marco.cozzini@eurac.edu
6-EURAC
Thomas Messervey thomas.messervey@r2msolution.com
7-R2M Solution
Marco Rochetti marco.rocchetti@r2msolution.com 7-R2M Solution
Uli Jakob uli.jakob@drjakobenergyresearch.de
8-JER
Samuel Baumeister s.baumeister@drjakobenergyresearch.de
8-JER
Johannes Steinbeisser j.steinbeisser@drjakobenergyresearch.de
8-JER
Johannes Stoldt johannes.stoldt@iwu.fraunhofer.de
9- IWU
Elena Gaboardi elena.gaboardi@youris.com
10- youris
Laura Trujillo l.trujillo@solera.de
11-Solera
Aysin Yeltekin aysin.yeltekin@estenerji.com
12-EST
Bakartxo Egilegor BEgilegor@ikerlan.es
13-IKERLAN
Enrico Callegati callegati.e@crit-research.it
14-CRIT
Diego Bartolome bartolome.d@crit-research.it
14-CRIT
Eleonora Bongiovanni bongiovanni.e@crit-research.it
14-CRIT
Stefano Cucchetti scucchetti@scmgroup.com
15-SCM
Giuseppe Lucisano glucisano@scmgroup.com 15-SCM
Rafael Postigo rpostigo@une.es
16-UNE
Table 2 – REEMAIN contacts details
The idea of a brief video to explain the whole project responds to the need to add public value to the achievements of the project by transforming complex scientific and technological results into media resources aiming to the web at large. The video is online on REEMAIN website and has been used at presentations, conferences and project’s events in general.

Figure 35 - REEMAIN video in the website homepage
It is a 3 minutes video in original languages with English voice over. It is made up of a series of short statements by members of the team on specific aspects of project’s scope and activities. The video presents the three case study of the project and main objectives of REEMAIN from an industry driven prospective: recovering lost energy, optimising production and integrating renewables.
The video is hosted on REEMAIN website homepage and on youris.com Youtube channel .

The video production took place in Rimini, Pavia and Aguilar de Campoo. Bossa made available footage produced at their plant in Adana.

A project logo was designed at the very start of the project and was made available for the consortium to brand project communication and templates. The logo is the one below:

Figure 36 - REEMAIN Project logo
The logo features a minimalist style font that shapes a symbolic factory from the letters M-A-I.
A version of the logo with the payoff included was delivered.

Figure 37 - REEMAIN project logo with payoff
The payoff develops on three lines and represents a structural element integrating the full logo.
The logo has two colours - light blue and grey- calling to mind the concept of sustainability in an industrial scenario. The Pantone code colours to be followed for the logo and that was used for all project communication templates, were:

Figure 38 - REEMAIN project colours