To support the Group’s ambitious Net-Zero targets, Mondi has upgraded its operational infrastructure to reduce energy consumption in the production of its packaging and paper products. These investments in energy and process efficiencies are being implemented across the business, contributing to the reduction of greenhouse gas (GHG) emissions from operations (Scope 1).
Operational excellence teams play a key role in Mondi’s Net-Zero strategy. A notable example comes from Mondi Richards Bay (South Africa), where a new, upgraded recovery boiler was commissioned in 2021. This initiative is expected to reduce GHG emissions by 250,000 tonnes per year, marking a significant milestone in the mill’s decarbonisation journey.
Following this achievement, the South African team further demonstrated their commitment by identifying additional opportunities for energy and process efficiency improvements. Over the past four years, a new energy-saving approach has been adopted, resulting in a 7% improvement in energy efficiency through a series of initiatives.
Mark Miller, Head of Reliability & Planning at Mondi Richards Bay, highlighted the team’s efforts, stating: “The team rose to the challenge of creating a more energy-resilient production environment at Mondi Richards Bay, showing great dedication and ownership in delivering these initiatives. The roadmap for future improvements is clear, with ambitious plans to further enhance the mill’s energy efficiency.”
Securing Business Value Through Energy Improvements
The energy team began their journey by reviewing key areas and existing energy assets at the site, including power boilers and evaporators. Over a two-year period, 14 energy efficiency projects were identified and executed. Additionally, a comprehensive benchmarking project revealed 16 more potential energy efficiency improvements, which have been integrated into the mill’s energy projects portfolio.
The team also participated in a pilot of the Group’s Energy Efficiency program, which was aligned with the ISO 50001 framework. This program offers a structured approach to improving energy use through the development of an energy management system (EnMS). At Mondi Richards Bay, the EnMS incorporated systematic processes and detailed energy-saving plans, driven by dedicated ‘Energy Champions.’ These efforts fostered a culture of ownership and passion for energy efficiency among the team. By the end of 2023, the mill had achieved ISO 50001 certification.
Energy engineer Yusuf Abbas summarised the success: “Achieving ISO 50001 certification in half the targeted time is a source of pride. The certification process has transformed mindsets, established clear processes, and fostered greater workforce ownership. Our achievements in energy efficiency and resilience at Richards Bay are now being implemented at other Mondi plants, which is highly rewarding.”
Recognising Outstanding Project Performance
The achievements of the Richards Bay mill were recognised with the ‘Driving Performance’ award at the 2024 Mondi Diamond Awards. This internal awards program celebrates standout projects across the Group, recognising excellence and sharing key lessons learned.
Photo: Mondi
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