Intelligent software to monitor your plant and continuously identify optimisation opportunities and wastage 24 hours a day.
ESP provides accurate data and specialist engineering capability to help you make the measurable decisions demanded in high uptime manufacturing industry environments, and to generate returns on investment that cant be sustained by traditional services alone.
“ESP is always there for us providing advice and helping us get the data we need to make the right decisions. They help us prioritise and work out where we can get the best gains.”
Operations Manager, Webstar
Don’t just take our word for it.
Here are some real world examples of what our manufacturing clients have achieved with our help. If they sound like the results you want, let’s talk.
The New Zealand Casings Company engaged ESP to establish their carbon footprint as part of its ongoing commitment to sustainability. The engagement included defining organisational boundaries, collecting scope 1,2,and 3 emission data and analysing it to build the carbon baseline. NZ Casings is also progressing with scope 2 emission reduction initiatives, with ESP monitoring the site’s hot water usage to baseline performance prior to an investigation of alternative carbon friendly ways to generate hot water. The New Zealand Casing company continue their effort to reduce their carbon footprint as they set out to make the best sausage casing in the world.
A lack of visibility of where energy was being used within the plant. all the way form lighting to machine efficiency. Manufacturing businesses have variable energy use due to production runs. It was essential that any outcomes could be measured against production runs.
Funded under EECA. ESP completed installed metering, followed up with an onsite review (simplified audit) with a monitoring and target report provided. We also established the measurement and verification plan to the IPMVP standard this allowed Integrated Packaging to understand the real savings aligned with their production output. Reports provided each year. Under ESP managed service regular site meetings and reviews occur to build business cases and incorporate onsite needs with the data driven insights and establish a validated operational plan.
The regular meetings ensure that Integrated Packaging has a regular operational process to review and ensure IP are on track to deliver to their targets. The team access Hub regular to monitor use particularly as they make changes and run different product mixes. The data has definately shown its value and IP are now looking to expand the amount of data collected. Have achieved wins of X% to date through improved energy efficiency and operational optimisation. The continue working toward their ultimate savings target of Y%.
The print industry is known for its tight margins. Webstar has utilised ISO as a framework to continuously measure, plan and improve for some time now. Energy, as one of manufacturings largest costs became a target for applying this process to ensure the business could measurable improve and sustain energy efficiency gains.
Webstar found ESP from the EECA website and soon identified the data-driven approach fitted well with their desired approach. ESP identified a range of quick wins and then looked to detailed monitoring of key plant to sustain those gains, and identify more.
Results have beaten expectations, with 5.7% reduction within the first year and now cumulative savings of over $250,000 resulting. On top of this, production costs have reduced by an estimated $500,000.
Vulcan steel had little visibility into energy usage at their site in Auckland. The site wanted assistance in sustained reductions in consumption and better data to make informed future investment decisions.
ESP installed sub-metering system followed by a Type 1 energy audit at the Auckland site identifying opportunities to improve machine utilisation, reduce compressed air usage, and upgrade lighting.
This engagement has resulted in 25% savings in the first year alone. This was achieved with better shift management to double production levels from baseline year. The factory has also upgraded their lighting to LED. Vulcan Steel continues to engage ESP in tariff negotiation at other sites.
Reducing production costs through data insights
Benefits realised by Webstar
- $56,500 energy savings in the first 12 months and $250,000 achieved to date, as a result of a 7.99% energy reduction
- Annual production costs reduced by an estimated $500k per annum, additional to energy savings through;
- Increased utilisation of key plant
- Service life of equipment extended reducing maintenance costs
- Reduced downtime and reduced servicing costs
- Increased productivity