Putting a lid on energy losses

• Spanish firm discovers a whole world of ways to save energy, materials and costs 
• Its resulting measures earn it a prize at the European Business Award for the Environment

Ramondín Cápsulas produces several types of lids and caps for a range of products including tin capsules (its flagship product), laminate capsules, champagne capsules, PVC capsules and screw caps. Ramondín manufactures over 50 % of the world’s tin capsules. Headquartered in Álava, the company exports nearly 75 % of its production and has a presence in the principal wine and spirits producing countries (Australia, Chile, the USA, etc.).

Aware of its environmental impact, the company developed a plan to reduce its carbon footprint by controlling greenhouse gas (GHG) emissions through up-to-date information on the quantity of gases emitted. Ramondín Cápsulas obtained this information by using a carbon footprint calculator which informed its GHG-capping strategy.

The majority of its emissions (79 %) came from raw materials used during manufacturing (tin, aluminium and PVC), followed a long way behind by electricity use (9 %), and then product shipping (8 %).

After identifying the principal areas of improvement and factoring all options for reducing emissions, Ramondin Cápsulas developed a series of measures:

• Partial (10 %) replacement of primary tin materials with secondary sources
• Explore solar (renewable) energy options; i.e. installing equivalent of 6 500 m2 of collectors in different places to generate up to 250 kWp
• Potentially using natural gas at the production facility instead of diesel oil and exploring the option to buy in 'green' energy
• Reinforce energy efficiency plans in factory and offices
• Option to use biodiesel in company vehicles
• Develop campaign to encourage green commuting by staff

Other measures to improve resource efficiency and waste production explored include:

• Replacing solvent-based ink by water-based ink in the production of tin capsules
• Optimising consumption of leftover paints through reformulation and/or recovery
• Applying eco-design criteria to minimise waste and packaging, and optimise manufacturing
• Reducing water consumption and wastewater discharge
• Reducing paper and toner consumption, improving the use of computer equipment

Key results

Implementing a package of measures, as illustrated above, led to:

• 1 974 tonnes of CO2 saved
• 25 % lower carbon footprint by using secondary materials
• 20 % energy savings
• 20% hazardous waste reduction
• 50% less wastewater and significant water savings

Ramondín Cápsulas’s effort to improve resource efficiency and reduce GHG emissions and waste earned it a prize in the European Business Award for the Environment, in the Basque Country section.