Essentra Components sees big upswing in machine replacement programme

Essentra Components has begun phase two of its electric machine replacement programme after 2021 saw 21 new machines installed across EMEA, US and APAC, seven more than initially planned, after significant improvements in phase one.

The second phase of the replacement scheme is expected to see 20 new electric machines installed throughout 2022, with seven already ordered in February this year. Some 39 hydraulic machines have been replaced to date, either at the end or final stages of their lifecycle.

With the initial goal to replace its entire portfolio with a more energy-efficient one by 2031, Essentra Components now expects the overhaul to be completed closer to 2028, thanks to the success it’s seen and the onboarding of new machine suppliers in local markets across APAC.

Energy savings reported of between 21% and 31%

The new machines are already proving their worth, says Essentra Components, with energy savings cycle-to-cycle being reported of between 21% and 31% across the four sites in the UK, Brazil, the US and China where machines were replaced in 2021. The changes have resulted in an average CO₂ reduction per machine of 2.41 tonnes – roughly 45 tonnes per year in total.

Due to global logistical challenges, Essentra expects the newer machines to be in place by June of this year. These new machines, some already in development and some yet to be ordered, will be replacing machines across the UK, the US and Spain. Phase three is slated to start in May this year to counteract possible future lead time extensions and mitigate any potential disruptions in deliveries and installations.

Chris Butler, divisional engineering manager at Essentra Components, says the first year of the machine replacement programme has been a great success: “We have managed to deliver seven more machines than we originally budgeted for. We are starting to see the benefits in reduced energy consumption, improved quality performance and reduction in cycle times.

Reduction of carbon emissions a key focus

"With the benefits being felt across the entire business, we’ve proritised and increased the original scope to hopefully reduce our original timline by two years. Whilst this is ambitious, the reduction of carbon emissions is a key focus for the business and indeed the sector.”

The original budget for the second phase has been increased by £500,000 to meet the growing demands of the business and the need for new equipment.

In total, Essentra expects to invest close to £7 million on the initial three phases, with the third phase set to begin in June of this year, ahead of the originally scheduled date.