The truck and bus chassis assembly plant is now capable of operating entirely off solar energy and is not only the first 100% carbon-neutral truck production site in Africa but also within the company's global production network.
Heiko Kayser, head of production at the Pinetown operation, said: "Installation of the solar - or photovoltaic (PV) - system commenced in August 2014 and was completed in less than six months. The project forms part of MAN's global climate strategy to reduce carbon emissions at its production sites in Europe, Africa, Asia and South America by 25% by 2020."
Geoff du Plessis, MD of the South African company, said this investment is not only a significant step in terms of environmental commitment, but also shows a longterm commitment to the region and its future. "Our products and services are all aimed to minimise their carbon footprint, and it is great to see that even our assembly plant contributes in this regard."
Said Kayser: "Prior to rolling out the PV project, we refurbished our roofing system at a cost of more than R5m to efficiently accommodate the solar panels and to install skylights and thermal insulation material to reduce demand for electric lighting, and to make our buildings cooler for our operators."
Of the 10,000m2 of roofing covering all buildings, 6,300m2 have been utilised to accommodate the PV installation. The 580kW system is capable of generating about 810,000kWh of power per annum, providing a surplus of energy that can be supplied to the metropolitan (eThekwini) grid.
Alan Swart, MD of Solaray, the company responsible for designing the system, said: "We sourced state-of-the-art equipment including inverters and solar panels from Europe which are able to generate power even in cloudy conditions, as well as mounting equipment from China. The PV system is grid-tied but is capable of becoming either semi-grid tied or completely off the grid with the inclusion of a genset or battery system respectively."
The system is linked to a webbased monitoring system that reports daily power consumption as well as electricity cost and CO2 savings. Furthermore, the online reporting software also delivers exception reports, enabling Solaray to rectify PV system issues swiftly.
The assembly plant has also installed a wash bay with a water recycling system which includes an oil-water separator. The system captures rainwater from the roof which is stored in tanks alongside the wash bay and is used to not only clean vehicles but also to test truck cabs for any leaks as they roll off the assembly line.
Employing 160 personnel, the plant is spearheading the corporation's climate change strategy with tangible benefits for all its stakeholders. Said Ncamsile Mbatha, SHEQ officer at the plant: "The fact that we are now using renewable energy means we are reducing pollution and our carbon footprint which is not only healthier for our people and our environment but helps to reduce production costs."
Lynette Kühn, SHEQ manager, said: "Both the PV installation and the water recycling system demonstrate MAN's commitment to corporate social responsibility and environmental protection. MAN Pinetown, being a CO2-neutral assembly plant and using water more responsibly, is setting a new benchmark for sustainability in the automotive industry in Africa."
Apart from the environmental and social benefits the green building will generate, impressive financial advantages will be realised, according to Kayser. "We have calculated that our energy cost savings for 2015 will be in the region of R1m with a CO2 saving of 860 tons per annum. These figures will improve over the following years."
Du Plessis regards the new carbon-neutral status of its main assembly plant as a powerful platform from which to gain ground in a domestic market that is not only consolidating via corporate mergers but is moving rapidly towards best practice procurement policies where environmental responsibility on the part of suppliers is a primary purchasing criterion.
"To become the first CO2-neutral plant in the MAN global production network is an example to our international colleagues of what can be achieved with commitment, passion and teamwork."
Source: Business Day
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