Energy audit & EMAS: how we prepare energy efficiency in plastics production
Energy is a central cost factor in plastics processing – and at the same time one of the biggest levers for greater sustainability. In Rotational Sintering and Moulding tools and material are heated and cooled down again in a controlled manner; thermal processes are therefore at the heart of our production. That is precisely why we systematically prepare for an energy audit within the framework of EMAS – and take energy efficiency into our own hands.
In this article, we explain briefly and clearly what an energy audit and EMAS actually are, why both matter for an industrial company, and what the process looks like in practice.
What is an energy audit?
An energy audit is a systematic analysis of how and where a company uses and consumes energy. The aim is to make energy flows transparent, identify savings potential and derive concrete measures for increasing energy efficiency.
In Germany, the procedure is governed by the DIN EN 16247-1 standard, which was revised in November 2022. A qualified auditor registered with the Federal Office for Economic Affairs and Export Control (BAFA) records the current state of consumption, assesses the main energy consumers and proposes economically reasonable efficiency measures.
Important: an energy audit according to DIN EN 16247-1 is not the same as the audit of an energy management system according to ISO 50001 – the energy audit is the one-off assessment, while the management system is the continuous process behind it.
What is EMAS – and how is it linked to the energy audit?
EMAS stands for Eco-Management and Audit Scheme and is the voluntary environmental management system of the European Union. It is considered one of the most demanding systems for sustainable business, covers all requirements of ISO 14001 and goes beyond them in key respects.
EMAS is characterised by:
- a comprehensive environmental review of the current state,
- the demonstrated continuous improvement of environmental performance,
- the active verification of compliance with legal regulations by a state-accredited, independent environmental verifier,
- as well as a validated, publicly accessible environmental statement with concrete key figures on energy, waste and emissions.
Energy consumption is one of the most important aspects here. Energy management can therefore be understood very well as part of a comprehensive environmental management system in line with EMAS – the energy audit provides the data basis, while EMAS ensures the lasting framework and external transparency.
Why does this matter? Obligations under the EnEfG and EDL-G
Since 18 November 2023, the Energy Efficiency Act (EnEfG) has tightened the requirements for operational energy management. The classification is based on the average total energy consumption of recent years:
- From 7.5 GWh per year, companies are obliged to introduce an energy or environmental management system in accordance with ISO 50001 or EMAS – usually within 20 months.
- Between 2.5 and 7.5 GWh per year, at least an energy audit in accordance with DIN EN 16247 must be carried out.
- From 2.5 GWh, economically viable savings measures must also be documented in implementation plans reviewed by external experts.
In addition, the Energy Services Act (EDL-G) obliges all companies that are not small or medium-sized enterprises (SMEs) and do not have an energy management system to carry out an energy audit every four years. Anyone operating a system in accordance with ISO 50001 or EMAS is exempt from the pure audit obligation. Breaches of these obligations are subject to fines – and there are reporting and verification obligations towards the BAFA.
For a manufacturing company such as Geratec, this means: anyone who uses energy in a significant scale anyway is far better off managing the topic strategically rather than simply working through requirements. A good energy audit regularly reveals savings potential that translates directly into lower operating costs.
How does an energy audit work?
An energy audit follows a clearly structured process. In simplified terms, it can be divided into five phases:
- Kick-off and data collection: consumption data for electricity, heat, fuels and – where relevant – mobile consumption such as the vehicle fleet are gathered.
- Measurement and inventory: the main energy consumers (equipment, heating, compressed air, lighting) are recorded and evaluated on site.
- Analysis: energy flows are assessed, load profiles examined and savings potential identified.
- Measures and report: economically reasonable efficiency measures are prioritised and documented in an audit report.
- Implementation and follow-up: the measures are implemented and their effect is monitored – in the EMAS context, this feeds into continuous improvement.
Thorough preparation – that is, complete, well-structured consumption data and a clear picture of one's own equipment – considerably shortens the audit and makes the results more robust.
Our approach: energy efficiency as part of how we see ourselves
For us, sustainability is not an afterthought but part of our mission statement. We rely on 100% recyclable PE products and work in a cost-conscious and environmentally friendly way. Preparing for an energy audit within the EMAS framework is the logical next step for us: we measure, assess and optimise our thermal processes in rotational moulding – so that our production remains more efficient, more transparent and future-proof.
Disclaimer: This article serves general information purposes only and does not constitute legal advice. The specific obligations depend on individual energy consumption and company status.