Manufacturing Plant

Manufacturing energy efficiency was at the heart of this project, which focused on replacing a regularly used but highly inefficient machine at a busy manufacturing plant. After installing a new, energy-efficient block moulding machine and integrating waste heat recovery, the site saw a significant drop in energy usage and required 80% fewer working hours compared to the previous setup. For more details, explore the full case study below.

The project scope at the insulation solution manufacturer involved the replacement of the block moulding machine with a newer more efficient model. This new model is fitted with a heat recovery loop which allows for the use of heat that was being lost previously. The next on-site benefit of upgrading the machine was the reduced need for forklift transportation of the product as the new machine allows for larger products to be made. This also means that the product can be stored more efficiently in the trailers used by the company therefore also reducing the fuel usage of transport on site.

The final benefit to the new block moulding machine is the reduction in defective products. This will reduce on site use of a compactor by 80%.