A W Precision Ltd

Process Optimisation: how we are reducing our annual energy usage & costs by over £57K!

Pro Enviro contacted us as a fellow member of Made in the Midlands – it turns out that we are almost neighbours, both being based just off the M6 in Rugby. As a member of Made in the Midlands, we took advantage of their offer of a free Energy Efficiency Assessment. This would establish if there were ways of reducing our energy consumption. Following the original free assessment with Pro Enviro, we proceeded with electrical metering of our equipment, after which Pro Enviro was able to suggest a Process Optimisation Strategy aimed at reducing our annual energy cost significantly.

Key elements of this strategy include:

  • Design of a new energy efficient LED lighting system to both improve lighting and reduce energy use by £12,300 per year,
  • Identification of very significant waste in our compressed air system and design of a new system saving £10,863 per year,
  • Specification of their Advanced Metering & Monitoring system called SEE Change ™ to monitor all our significant energy-using equipment. This allowed ongoing identification of waste and further process optimisation - large potential savings of £32,843 per year were identified,
  • Identification of improvements to our Power Factor Correction equipment, saving £1,172 per year,

For the first time, we understand where energy is being used in our manufacturing processes and how we might control and minimise this.  Quantifying savings in term of annual tonnes of CO2e allowed us access, with administrative assistance from Pro Enviro, to substantial capital grant funding for the projects.

In all, savings of £57,178 per year in energy usage and 136.2 tonnes of CO2e were identified and we are now in the implementation stage.

This would not have been possible without the service provided by Pro Enviro’s consultants, for which we are clearly very grateful. Using their extensive energy engineering knowledge and experience, they have been able to design, cost and implement improvements quickly and efficiently, with the minimum of disruption to our day to day processes. I have no hesitation in recommending them to other businesses that want to ensure they minimise their Carbon Footprint, implement an effective Low Carbon Strategy, and most importantly, save money on their energy bills!

Mr Andrew Whitworth
Managing Director, A W Precision Ltd

Elite Plastics

Like every business, we have been concerned about the rapid rise of energy costs and our energy efficiency.  Thanks to the support of Pro Enviro, who helped us identify several areas for improvement and access the most appropriate funding for all of our requirements, we have been able to implement a low carbon strategy and effectively address the potential for cost savings and carbon reduction – all of which we are taking action on.  This will reduce our considerable annual energy costs (£317,000) by £62,000 and 267 tonnes of CO2e.  With the help of Pro Enviro, we will continue to manage, understand and improve our use of energy throughout Elite Plastics facilities and processes.

Dave Gummerson
Managing Director, Elite Plastics

James & Williams

James & Williams manufacture a wide range of high-quality coffin handles and coffin fittings at their own factory in Herefordshire. This family run business has traded as Decorative Metallisers/James and Williams since 1968 and specialised in vacuum metallising for decorative products and funeral fittings.

“In the early 1970's we started to manufacture our own coffin fittings and have built up a comprehensive range of our own designs and tooling. In September 2017 we were contacted by Pro Enviro, as the Approved Supplier for Herefordshire & Worcestershire County Councils Business Energy Efficiency Programme (BEEP), who offered us a free Business Energy Efficiency Review.  Initially, we were a little cautious about proceeding, as we felt that there must be ‘a catch’!  However, we were soon re-assured, and as a direct result of the free (and comprehensive) Energy Efficiency Review it was identified that James and Williams could achieve annual financial savings of up to £10,892 and 33.9 tonnes of CO2e by implementing the report's recommendations.  There was a significant opportunity to save costs by replacing the four existing PECO injection moulding machines with a single more efficient machine.  Nersi, from Pro Enviro, and Zoe, from WCC, helped make this happen along with sourcing a substantial BEEP grant to support us financially with our new purchase.  The whole process was effortless, as they guided us through every stage, helping to save time by clearly explaining each step and ensuring everything was done correctly.  Between them they made the application and implementation quick and easy, and both Nersi and Zoe were a pleasure to deal with, offering their time, expertise and patience as we moved this project forward.  In addition, the BEEP review identified that we would save money by replacing our old and inefficient lighting with new LED lighting – again Nersi was instrumental in finding a source of financial support (via The Carbon Trust) to help us fund this project.  We would not hesitate to use Pro Enviro in the future and would highly recommend their services to other businesses.”

Ray Williams and Gill Horton
Directors, James & Williams

Galebreaker Agri

“Thanks to the Pro Enviro team carrying out a Business Energy Efficiency Assessment, we identified several ways we could further improve our energy efficiency. Pro Enviro’s findings identified that, by making their recommended changes, we could achieve annual financial savings of up to £18,872 and 62.81 tonnes of CO2e. They then helped us prioritise the required changes, identify and access the best available funding opportunities, and supported our grant application processes. As a result, and with the minimum of disruption, we have improved our working environment considerably and reduced our energy bills. Pro Enviro will continue to support us with meeting our energy efficiency targets and the implementation of our low carbon strategy, and I am happy to recommend them to other businesses wishing to develop a low carbon strategy and reduce their own energy costs.”

Keith Hardie
Special Projects Director, Galebreaker Agri
Click here to read their case study

Brockway Carpets

Thanks to Nersi Salehi and the Pro Enviro team, we now fully understand the viability of in-house solar electricity generation and battery storage at our manufacturing operation in Kidderminster.  Pro Enviro designed an efficient and cost-effective PV system and battery storage facility and then analysed the potential installation cost and energy savings in a comprehensive report.  This report assessed all installation costs, potential energy generation and savings, analysed the return on investment and identified potential grant funding streams available to support this project.

Pro Enviro also made an effective presentation to our board to ensure that all the relevant facts and figures were available to the senior management team to help our decision-making process.  I am happy to recommend Pro Enviro to any business that wishes to investigate the potential of in house sustainable energy generation and battery storage.”

Nick Walley
Director, Brockway Carpets, May 2018.

Newtown Packaging LTD

Pro Enviro has recently helped us with a number of energy reduction and cost saving projects.  They first contacted us on behalf of Worcestershire County Council, as their nominated energy efficiency advisors for the recently launched Business Energy Efficiency Programme (BEEP).  They began with a detailed review of our manufacturing facilities in Redditch, and combined it with some clever analysis of our last twelve months energy bills, looking at our consumption, trends and costs.  The BEEP programme is EU funded, so the review, written report (analysis and recommendations) and the follow up support cost us nothing.

The overall findings of the BEEP review identified our biggest and most immediate challenges to improve our current heating system, to reduce wasted heat and to become more energy efficient.  Pro Enviro recommended several ways to help us make improvements-including installing a fast acting plastic door curtain to reduce heat loss from the delivery bay, and the installation of 4 de-stratification fans, to move warm air that accumulates at a high level, back down into the lower levels.  Pro Enviro was then instrumental in helping us with the design of the system, selection of contractors and access to grant funding (of 40%) for the implementation of their recommendations -we received around £3200.00 from the capital investment support scheme of the BEEP programme.

They also identified major opportunities by improving our lighting system throughout our offices and production areas.  The lighting project involved the removal of the old inefficient luminaires from our offices and production facility, and replacing them with 73 modern LED fittings controlled by daylight and motion sensors.  The work was carried out with no disruption to our staff or day to day productivity.  They informed me that our lighting project was eligible for a significant Carbon Trust Grant funding and then supported us with the grant application process until we received the funds.

The cost savings to us have been considerable -the fans help us save around £700 annually, with an annual saving of 2.8 tonnes CO2, and a payback time of just over three years.  The quick acting door curtain will considerably improve the working environment of the warehouse and reduces our gas consumption for heating.  The new lighting system will save £3,400 annually along with a reduction in our carbon footprint of 11.6 tonnes of CO2.  The payback time for this project will be 2 years 6 months.

The Pro Enviro team have been easy to work with, and are competent, approachable and knowledgeable.  They are clearly experts in their field, and we are very satisfied with how they used their expertise to design, cost and implement these energy efficiency solutions which will significantly reduce our annual energy bills.  In addition, we were very impressed with their considerable knowledge about, and ability to access, all available grant funding opportunities -this really helped us to implement these projects quickly, and will result in a significant reduction in payback time.  We continue to work with Pro Enviro on other energy saving projects, and I have no hesitation recommending them to other businesses.

Pawel Czapiewski
Head of Purchasing,  Newtown Packaging LTD

The Patent Ferrule Company Limited

Pro Enviro have recently undertaken several projects on our behalf concerning energy conservation.

1) Firstly to advise and then coordinate the obtaining of a grant for the installation of LED Lighting in our 18,000 sq. ft. production area. Secondly to advise and as above help getting a grant for the installation of a new Air Compressor.  Thirdly again to advise and help obtaining a grant towards recovery from H.M.R.C. a portion of Climate change levy paid on our energy bills.  Finally to advise and supply a new Electricity Capacitor to reduce our KVA demand.

2) All of the above have been introduced to help us conserve energy and thereby reduce our costs.

3) Without help from Pro Enviro we would not have had the knowledge or the expertise to be able to carry out these projects.

4) The savings so far have been well in line with expectations but probably the catalyst which got us going was the BEEP grants which we got towards the capital expenditure.

The whole experience of dealing with Pro Enviro has been extremely informative and helpful.  As a company to deal with they are both efficient and at the same time friendly and a pleasure to do business with.

S. C. Shoebotham
Managing Director, The Patent Ferrule Company Limited