Energy Wastage Solutions At Elcomponent

Introduction

The Client is a leading UK food producer and supplier, known for its premium, fresh, and added-value food products. With multiple food processing facilities across the UK, the company operates in a highly competitive and energy-intensive industry, requiring efficient energy management and effective cost control. To further enhance its sustainability initiatives and meet compliance standards, the client sought to implement an advanced energy monitoring system to track and optimise energy consumption across its production sites.

Challenges

The company faced several significant challenges:

Energy Efficiency: Identifying inefficiencies in energy usage across various food processing facilities, including production lines, refrigeration, heating, and cooling systems.

Compliance: Achieving and maintaining compliance with ISO 15001, which focuses on energy management standards.

Proactive Monitoring: The need for a robust system to proactively detect energy wastage and identify areas for improvement during varying production shifts and volumes.

Harsh Working Environments: Ensuring the system could operate effectively in the demanding environments of food production facilities.

Solution

To address these challenges, the client partnered with Elcomponent to implement a comprehensive energy monitoring and management solution. The system involved:

400+ Meters: Over 400 meters for electricity, water, gas, and heat were installed across various production sites, including sub-metering for major energy consumers such as production processes, heating and cooling, refrigeration and compressors.
High-Power Wireless Systems: Remote meters were connected via the site LAN and robust wireless networks, allowing seamless communication of energy data.
Cloud Reporting & Alerts: Online reporting and automated alerts allowed the client to proactively detect issues, enabling faster identification of wastage and inefficiencies during different shifts and production volumes.
Energy from Renewable Generation: The system also tracked energy from solar production, allowing the company to manage on-site demand and export excess energy to the grid.
ISO 15001 Compliance: The solution ensured compliance with ISO 15001 by providing continuous monitoring and reporting of energy consumption, contributing to the company’s overall carbon reduction strategy.

Implementation Process

The installation process followed a well-planned and structured approach:

Data Integration: All energy data, including from renewable sources, was integrated into Elcomponent’s MW2 energy management platform.
Real-Time Monitoring: The system provided real-time energy vs. production output metrics, crucial for sustainability reporting, particularly for major UK supermarkets requiring this data.
Parameter Measurement: In addition to energy consumption, parameters such as CO2 usage and localised temperature were measured, providing comprehensive insight into the company’s overall environmental footprint.
Maintenance & Support: Elcomponent’s in-house engineering and IT support teams ensured seamless service, hardware maintenance, and upgrades to the infrastructure across all sites.

Business Impact

The energy monitoring and management system had a significant impact on the company’s operations and sustainability efforts:

Faster Issue Detection: Automated alerts and real-time monitoring allowed the company to quickly detect and address energy wastage, leading to more effective operational management.
Energy Savings & Compliance: The system facilitated energy-saving initiatives, contributing to both operational cost reduction and compliance with ISO 15001.
Water Usage Optimisation: The company focused on reducing water usage in its production facilities, using Elcomponent’s MW2 M&V tool to report savings achieved.
Decarbonisation: The system supported decarbonisation schemes by helping the client reduce reliance on gas and electricity, further advancing its sustainability goals.
Enhanced Reporting: Visual dashboards and automated management reports provided stakeholders with real-time data on energy usage, savings, and sustainability performance, supporting the client’s commitment to sustainability reporting for major retailers.

Conclusion

The installation of the energy monitoring and management system, supported by Elcomponent, has enabled the client to take significant strides toward energy efficiency and sustainability. By leveraging real-time monitoring, automated alerts, and detailed reporting, the company has gained full visibility over its energy usage, supported compliance with ISO 15001, and contributed to its carbon reduction strategy. The seamless integration with existing systems and ongoing support from Elcomponent ensures the system’s continued success in driving energy savings and sustainability across all facilities.