Boosting sustainability in the industrial, automotive & aeronautical sectors with 30% energy savings
It’s no surprise that manufacturing is one of the most energy-intensive industries out there. But this means that there are also numerous opportunities for energy efficiency measures and savings.
Bonaprene, the UK’s leading polyurethane manufacturer, had growing concerns about sustainability and high energy usage. So they sought a solution from Best.Energy Partner, Zeronify, to reduce energy consumption, without impacting production.
Click below to take a closer look at the Bonaprene case study for more details:
The Challenge
Bonaprene faced multiple challenges:
- They had manual processes with limited automated controls.
- The heating equipment was activated too early and left on too long.
- Machines were running 24/7, even when the plant was not operational.
- High-energy intensity machines were running flat out, despite fluctuating demands.
The Solution
Zeronify installed the award-winning Eniscope energy management system to gather real-time energy data across 2 production lines. This helped to identify and focus on inefficient processes and practices that were costing Bonaprene money and negatively impacting the environment.
This system enabled 24/7 analysis of every piece of machinery on those 2 production lines, highlighting opportunities for improvements and savings fast.
The Results
Thanks to the advanced and granular data provided by Eniscope, Bonaprene was able to identify 30% energy savings with opportunities to:
- Optimise start-up and shut-down times, reducing the unnecessary usage of heating equipment.
- Upgrade settings to reduce energy usage when the site is not operational.
- Set alarms to highlight when assets are running out of hours and wasting energy.
- Implement variable speed drives and pressure sensors to match demand and supply.
With total energy visibility across their 2 production lines, Bonaprene saved over £20,000 on annual energy bills. Collaborating with Best.Energy Partner, Zeronify, continues to deliver ongoing savings worth more than 5 times the client’s initial investment, generating significant value straight to their bottom line, and boosting their sustainability credentials.
