THE ENERGY-EFFICIENT PRODUCTION LINE
​The IVECO plant in Madrid, Spain, (photo below) also achieved Gold status in the World Class Manufacturing (WCM) program in 2017. Its production line demonstrates CNH Industrial’s many sustainability initiatives to improve efficiency and reduce energy consumption:
Reducing energy consumption through WCM
Saving and generating energy
The IVECO factory in Valladolid is the second CNH Industrial site to achieve WCM Gold status – since the IVECO plant in Madrid, Spain, did so two years ago. Despite the highly complex production process of the IVECO Daily van range – which includes 11,000 product configurations, around 350 colors and six different body types – the Valladolid plant's continued efforts to eliminate waste and reduce energy consumption let to impressive marks for the WCM Energy pillar during third-party audits.
As well as saving energy, the Valladolid plant also generates some of its own. This is thanks to the newly installed solar-powered SmartFlowerTM a photovoltaic energy generator that follows the sun's path in the same way that sunflowers do. By keeping its panels at a 90-degree angle to the sun, it generates up to 40 percent more energy compared to static panels, and its self-clean and self-ventilation functions ensure minimal maintenance is required.
Similarly, the Madrid plant installed the SolarWall® – a custom-designed cladding system fitted onto its exterior walls that uses solar energy to heat and ventilate its interior spaces. Solar-heated air is distributed throughout the building via the existing HVAC (heating, ventilation and air-conditioning) system, reducing the energy load on the conventional heating system.
CNH Industrial continually invests in energy-efficiency initiatives at all of its plants around the world. Some of these are simple modifications that produce impressive results. They include redesigning industrial processes, insulating buildings, introducing LED lighting, and retro-fitting improvements to existing equipment, among many others.
Roofs are regularly upgraded, and walls insulated to save energy. Rapid-close doors are installed wherever possible to keep heat in.
Pumps, fans and motors
Ventilation manages and helps regulate air changes on the shop floor. Aeraulic systems have been introduced in plants to check and optimize the air flow generated by pumps, fans and motors, which have also been fitted with inverters to modulate electricity use, optimizing consumption and reducing emissions.​ ​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​
HVAC systems have been upgraded and made more efficient, and ovens such as those used during the painting process have been insulated to reduce overall energy consumption.Lighting
CNH Industrial has an ongoing program of upgrading lighting both inside and outside its plants, installing high-efficiency LED lights, presence detectors and dimmers. Wherever possible, skylights are incorporated into the roofs of buildings to exploit natural daylight, which not only helps reduce energy consumption, but also enhances the working environment.
Compressed air is used during assembly, painting and welding processes. Overall pressure has been lowered to save energy, and the air pipes are continually monitored to ensure they are in optimal condition to improve efficiency and modulation. During idle periods, heavy compressed-air machinery is shut down in favor of portable compressors.
Heat recovered from painting ovens and compressors is reintroduced into the system and used for the generation of chilled water to reduce the amount of primary energy required.
​​​​​​Training and tangible results
- 90% of total electricity consumption to be derived from renewable sources
- -60% reduction in CO2 emissions per production unit at Company plants worldwide vs 2014 levels
- -30% reduction in energy consumption per production unit at Company plants worldwide vs 2014 levels