elcomponent.co.uk

16th May 202516th May 2025

Case Study – Energy Monitoring System Installation at UK Leading Preparation and Food Processing Plant

Introduction

The Client owns a number of processing factories, and is a leading organisation in the food industry, has long been committed to improving operational efficiency and reducing its environmental footprint. Recognising the importance of energy consumption in their production process, the management decided to implement an energy monitoring system to gain better control over their energy usage and make informed decisions for sustainability and cost savings.

Challenges

The Client was facing several challenges related to energy management, including:

Inadequate Energy Data: The factory lacked a comprehensive system to monitor energy consumption, which made it difficult to identify inefficiencies or opportunities for optimisation.

High Energy Costs: The rising cost of energy was impacting the factory’s operational expenses, cutting into profit margins.

Sustainability Goals: The company aimed to reduce its carbon footprint and align with environmental sustainability goals.

Regulatory Compliance: Compliance with energy usage regulations and reporting requirements was becoming increasingly complex.

Solution

The factory management decided to address these challenges by installing an advanced Energy Monitoring System (EMS) from Elcomponent with the following components:

Electricity, Gas and Water Meters: Communicating meters were installed across critical points in the factory to measure real-time energy consumption accurately.
Data Acquisition System: Data acquisition units were employed to collect, process, and store energy consumption data from smart meters.
Software Platform: A user-friendly software platform was implemented to provide real-time data visualisation, historical data analysis, and reporting capabilities.

Implementation Process

The installation of the Energy Monitoring System followed these steps:

Assessment and Planning: A team of experts conducted an energy audit to identify the most critical areas for monitoring and set up a detailed plan for implementation.
Equipment Selection and Installation: meters were selected based on the specific needs of the factory and strategically placed. Data acquisition units and software were installed and configured.
Training and Integration: Factory personnel received training on using the software platform and integrating the EMS with existing systems.
Real-time Monitoring: With the system in place, real-time energy dashboards became available for analysis and decision-making.

Results

The implementation of the Energy Monitoring System led to significant improvements in the factory’s energy management:

Cost Reduction: By identifying energy inefficiencies and optimising energy usage during peak hours, the factory reduced its energy costs by 5% within the first year.
Sustainability: The EMS allowed the factory to reduce its carbon emissions and aligning operational activity with its sustainability goals.
Operational Efficiency: Real-time data and alerts helped the factory’s maintenance team respond to issues more rapidly, reducing downtime.
Regulatory Compliance: Providing accurate data for the clients regulatory reporting

Future Plans

The Client is now considering further enhancements to their EMS, including the integration of production data to provide predictive energy consumption based on factory output. Expansion on the other sites is underway, and similar results are expected at each.

16th May 202516th May 2025

Case Study: Energy Monitoring System Installation for a Leading UK Provider of Wall, Roof, and Landscaping Innovations

The Client

The Client is the UK’s leading provider of wall, roof, and landscaping innovations, offering over 1,000 products across brick, roof, paver, facade, and blocks. Committed to sustainability, the company sought to reduce energy consumption across its energy-intensive operations with multiple manufacturing sites.

Challenges

The company faced several key challenges:

Sustainability Goals: Integrating sustainability into the core company strategy by reducing energy consumption and carbon emissions.

Energy Management: Managing a multi-million pound annual utility spend across multiple sites, making it essential to identify and implement energy-saving measures.

Data Accuracy: Achieving accurate, real-time data monitoring for effective energy management and decision-making.

Solution

To address these challenges, the company implemented a comprehensive energy monitoring system with support from Elcomponent. The solution included:

300+ Meters: Installation and commissioning of more than 300 meters for electricity, water, gas, and heat across 12 sites in the UK.
Real-time Data: Real-time data collection and monitoring via a cloud-based data platform.
Flexible, Robust System: A multi-site capable energy monitoring system tailored to the specific needs of each factory.
Turn-key Solution: A complete solution including installation, metering individual loads, on-site data logging, and a cloud-based software package.

The Elcomponent system was designed to monitor and verify energy-saving projects, allowing the company to analyse energy usage across its entire portfolio efficiently.

Implementation Process

The installation of the Energy Monitoring System followed a structured approach:

Assessment and Planning: Initial assessment to identify critical areas for metering and develop a detailed installation plan.
Installation and Commissioning: Installation of meters and integration with the cloud-based data platform, ensuring real-time data collection and logging.
Training and Integration: Training on-site personnel to use the monitoring system and integrating it with existing operational systems.
Real-time Monitoring: Enabling continuous, real-time monitoring of energy usage across all sites.

Business Impact

The implementation of the Energy Monitoring System had a significant positive impact on the company’s operations:

Energy Savings: Enabled identification and implementation of energy-saving measures, such as upgrading air compressors to variable output, which resulted in verified savings of £9,000 and 65 tonnes of CO2 annually on a single compressor.
Cost Reduction: Improved control over energy expenditure, allowing for reinvestment in efficient and innovative manufacturing processes.
Operational Efficiency: Real-time data and monitoring facilitated better energy management and supported the company’s sustainability goals.

16th May 202516th May 2025

Case Study: Energy Monitoring and Management System Installation for a Leading UK Food Producer

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.

16th May 202516th May 2025

Case Study: Energy Monitoring System Installation at a Large Hospital Complex in Central England

Introduction

The Client, a large hospital complex in central England, provides major treatment and emergency services for the surrounding area. With a constant need to manage costs effectively, the hospital sought to implement a robust energy monitoring system to gain better control over its energy usage and reduce operational expenses.

Challenges

The hospital faced several key challenges:

Cost Management: The need to continuously reduce operational costs while maintaining high standards of patient care and services.

Energy Efficiency: Identifying and addressing areas of energy wastage to improve overall efficiency.

Real-time Data Monitoring: Implementing a system that provides accurate, real-time data to facilitate informed decision-making.

Solution

To address these challenges, the hospital decided to install an advanced energy monitoring system with support from Elcomponent. The solution involved:

120+ Meters: Installation and commissioning of over 120 meters across the hospital site.
Large Site Coverage: Comprehensive metering to cover the extensive hospital complex.
Cloud Platform: Real-time data collection with half-hourly readings sent to a central cloud-based platform.

The hospital took charge of installing the meters and logging system to minimise costs, while Elcomponent provided expert support and commissioning services to ensure the project’s success.

The Engineering Manager of the hospital remarked, “The way the system comes together enabled us to use our own on-site resource to complete a major part of the project and use our financial resource to target other needy areas. I would work with Elcomponent again who are both professional and value for money. I particularly like the fact that there are no user licenses and anyone with an interest can log in to the software.”

Implementation Process

The installation of the Energy Monitoring System followed a structured approach:

Assessment and Planning: An initial assessment to identify critical areas for metering and planning the installation process.
Installation and Commissioning: The hospital installed the meters with guidance from Elcomponent, who then commissioned the system to ensure accurate data collection and integration with the cloud platform.
Training and Integration: Training hospital staff to use the monitoring system effectively and integrating it with existing hospital management systems.
Real-time Monitoring: Enabling continuous, real-time monitoring of energy usage across the hospital complex.

Business Impact

The implementation of the Energy Monitoring System had a significant positive impact on the hospital’s operations:

Energy Reduction: The system enabled the hospital to identify and reduce energy wastage, leading to significant energy savings.
Cost Control: Improved control over energy expenditure contributed to overall cost reduction, freeing up resources for patient care.
Operational Efficiency: Real-time data and monitoring allowed for more effective energy management, ensuring that the hospital could maintain its high standards of service while managing costs efficiently.
User Accessibility: The software’s lack of user licenses meant that anyone with an interest could log in, fostering greater engagement and oversight from various stakeholders.

Conclusion

The installation of the Energy Monitoring System at the large hospital complex in central England, supported by Elcomponent, has proven to be a valuable investment. The system has enhanced energy efficiency, reduced costs, and provided the hospital with the tools necessary for effective energy management. By leveraging real-time data and advanced monitoring capabilities, the hospital is now better equipped to control energy usage and focus resources on delivering exceptional patient care.

16th May 202516th May 2025

Case Study: Energy Monitoring System Installation at the UK’s Leading Drinks Manufacturer

Introduction

The Client is the UK’s leading drinks manufacturer with multiple manufacturing locations across the country. As part of their commitment to sustainability, the company aims to achieve net zero carbon emissions by 2040, if not sooner. To support this goal, the company sought to implement a comprehensive energy monitoring system to optimise energy usage and reduce their carbon footprint.

Challenges

The drinks manufacturer faced several key challenges:

Sustainability Goals: Achieving ambitious targets to reduce carbon emissions and reach net zero by 2040.

Energy Efficiency: Identifying areas of energy wastage and implementing measures to optimise energy usage across multiple sites.

Data Management: Ensuring accurate and real-time data collection from a large number of meters for effective monitoring and decision-making.

Solution

To address these challenges, the company partnered with Elcomponent to install an advanced energy monitoring system across three of its manufacturing sites. The solution included:

140+ Meters: Installation and commissioning of over 140 meters across three sites.
Existing & New Meters: Utilising existing metering infrastructure and supplementing with new meters as needed.
Real-time Data: Providing half-hourly readings in real-time to a central cloud-based platform.
Cloud Platform: Utilising the site LAN as a communication backbone, with logged data from meters and a local copy of the database stored for redundancy.

Elcomponent’s role involved supplying, installing, and commissioning the systems, ensuring seamless integration with the existing infrastructure.

Implementation Process

The installation of the Energy Monitoring System followed a structured approach:

Assessment and Planning: An initial assessment to determine the metering requirements and plan the installation process.
Installation and Commissioning: Elcomponent installed the meters and integrated them with the site LAN, ensuring real-time data collection and local data storage.
Training and Integration: Training site personnel to use the monitoring system effectively and integrating it with the company’s existing management systems.
Real-time Monitoring: Enabling continuous, real-time monitoring of energy usage across the three sites.

Business Impact

The implementation of the Energy Monitoring System had a significant positive impact on the drinks manufacturer’s operations:

Energy Reduction: The system enabled the identification and reduction of energy wastage, contributing to significant energy savings.
Cost Control: Improved control over energy expenditure helped in reducing operational costs.
Operational Efficiency: Real-time data and monitoring allowed for more effective energy management, ensuring the company could meet its sustainability targets efficiently.
Sustainability Progress: The accurate and timely data collection supported the company’s journey towards achieving net zero carbon emissions by 2040.

Conclusion

The installation of the Energy Monitoring System at the UK’s leading drinks manufacturer, supported by Elcomponent, has proven to be a valuable investment. The system has enhanced energy efficiency, reduced costs, and provided the company with the tools necessary for effective energy management. By leveraging real-time data and advanced monitoring capabilities, the company is now better equipped to control energy usage and progress towards its net zero carbon goals. Elcomponent’s expertise in integrating new and existing metering systems, along with their professional support throughout the project, has been instrumental in the success of this initiative.