1. Introduction

The plastics processing sector represents a large and growing sector of the Canadian economy for which energy efficiency is a key issue. This sector has worked co-operatively with provincial/territorial and federal government agencies to promote resource conservation and to highlight opportunities to its stakeholders on how to improve energy performance. An excellent example of this collaboration is the Guide to Energy Efficiency Opportunities in the Canadian Plastics Processing Industry, which was prepared as a joint effort between the Canadian Plastics Industry Association (CPIA) and the Canadian Industry Program for Energy Conservation (CIPEC). This guide is intended to be a helpful tool that can be used in conjunction with existing skills and knowledge among stakeholders who share an interest in the plastics processing sector.

This guide has been updated from the original document produced in 1997. The new version provides additional information and guidance in the area of greenhouse gas emissions reduction. The purpose of this guide is to help plastics manufacturers identify equipment, auxiliary systems and process improvements that will reduce production costs, improve their competitive position, reduce pollution, and conserve energy, water and other resources.

Since the publication of the original guide in 1997, Canada has introduced a national strategy to reduce the country's total greenhouse gas emission by 60 to 70 percent by 2050. While the Canadian plastics processing industry is not a major emitter of greenhouse gases, plastics processors can reduce costs and greenhouse gas emissions by conserving energy. Reducing greenhouse gases and how it relates to the plastics processing industry are described in Chapter 3 of this guide.

The primary users of this guide will be the executives in the plastics processing industry who make equipment purchases, process improvements and maintenance decisions in a competitive environment. However, the audience also includes all stakeholders in the plastics manufacturing industry. Other readers who will benefit include owners, managers, production supervisors, maintenance staff, employees, suppliers, designers, consultants and industry associations. For readers who are not familiar with the industry and its technology, Chapter 5, "Generic Processes and Auxiliary Systems Descriptions," offers simplified process descriptions and generic process diagrams.

The processes described herein are estimated to include over 90 percent of the market activity in Canada. The significant thermoplastic processes that are discussed include the following:

• profile extrusion;
• thermoplastic-injection moulding;
• flat film or sheet extrusion;
• blown-film extrusion; and
• blow moulding.

The two thermoset processes that are discussed include the following:

• compression moulding of thermoset plastics; and
• foam moulding.

In addition to these processes, auxiliary equipment and general plant systems common to most plastics operations are also discussed. The plastics processing industry uses a broad range of technologies, not all of which are discussed in this guide. A more complete listing of processes may be found in Appendix III, which outlines the scope of generic plastic manufacturing processes currently used in Canada.

An effective resource conservation and pollution prevention program requires the following components:

1. An understanding of current performance in terms of resource consumption and efficiency.
2. A detailed site-specific assessment to identify specific technical opportunities for improvement.
3. A management practices framework that will support and influence the implementation of conservation opportunities.
4. A continuous improvement approach to resource conservation activities.

As the level of technical analysis required for these components is beyond the scope of this guide, only an introduction to these components is provided here.

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