CO2e Reduction Through Sustainability Initiatives with Compliance to CCA Targets

Case Study Springvale EPS Ltd

About Us

Springvale EPS Ltd (Springvale) is the UK’s leading manufacturer of Expanded Polystyrene (EPS).

For over 50 years, we have supplied premium, high performance EPS products into the house building, construction, caravan, and other industries.

Our commitment to manufacturing excellence, technical expertise, and outstanding customer service has always been at the heart of our growth. Sustainability and responsibility are key pillars of how we operate, and our approach CO2 reduction reflects our commitment.

We are proud members of the British Plastics Federation (BPF), actively engaging with the wider plastics industry and benefiting from the resources, guidance, and collaborative opportunities the BPF provides. This partnership supports our continuous improvement and reinforces our leadership in responsible EPS manufacturing.

Overview

Between 2017 and 2024, Springvale EPS Ltd (Springvale) achieved a 40% reduction in CO2e emissions. This significant drop reflects our ongoing commitment to environmental responsibility, process efficiency, and sustainable operations.

* SEC (Specific Energy Consumption) measures kWh per kg of processed raw material, which is a normalized performance metric used within our Climate Change Agreement (CCA).

Key Sustainability Actions Implemented

1. Water Recovery Systems

  • Water Recovery to Boilers: Captured and reused process water, reducing demand for fresh water and energy to heat it.
  • Boiler Room Holding Tank: Added recirculation and holding systems to minimize water wastage and reheating energy.

2. Operational Efficiency

  • Operation on Cutting Line: Optimized workforce allocation and reduced energy consumption by redesigning workflows.
  • Efficient Burner System Installation: Installed a high efficiency gas burner on our steam boiler, reducing gas usage and improving steam production efficiency.

3. Energy Consumption Reduction

  • LED Lighting Conversion: Replaced all plant and office lighting with efficient LEDs, significantly lowering electrical usage.
  • Boiler Pressure Optimization: Lowered boiler operating pressure, maintaining performance while reducing energy usage and cutting CO2e output.

Impact

  • Delivered 1,494 tonnes less CO2e since 2017.
  • Achieved a 4.19% drop in SEC from 2017 to 2024, despite production fluctuations.
  • Improved alignment with our Climate Change Agreement and ESG responsibilities.

Challenges in Reducing SEC Despite CO2e Improvements

While total CO2e emissions have fallen significantly reflecting real energy and fuel savings – the Specific Energy Consumption (SEC) metric has proven more difficult to lower. Factors include:

  • Variable Production Volumes: Lower output in certain years results in less efficient energy distribution per kg of raw material, increasing SEC.
  • Fixed Energy Loads: Baseline energy demands (e.g., lighting, heating) remain constant even when production slows, inflating SEC during quieter periods.
  • Product Changes and Customer Requirements: Shifts to more complex product specifications may require more energy per kg of raw material processed.

These complexities show that SEC can be influenced by production variability and infrastructure changes that don’t always scale proportionally with output.

Conclusion

This case study demonstrates that a strategic focus on energy efficiency, waste heat recovery, and operational streamlining at Springvale can yield meaningful environmental and financial returns. Our next steps include exploring renewable energy, investigate preventive/predictive maintenance systems, and altering shift patterns to match demand.

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