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Powering efficiency: An industrial approach to reducing energy costs and carbon footprint
In 2023, volatile energy prices put significant pressure on a leading building materials company's bottom line, creating an urgent need to improve energy efficiency and reduce costs. To address this challenge and lower its carbon footprint, the company partnered with BrightWolves to design and implement a strategic energy reduction plan.
Challenge
Our client faced sharp energy cost increases due to an expiring gas hedge contract and the Ukraine war’s peaking impact on prices. Although they had set internal energy goals, soaring costs demanded more decisive action.
80%
2M
12%
Energy usage targeted
EUR Annual savings
Energy reduction
Approach
Our solution focused on key actions:
Data-driven analysis: We thoroughly analyzed the plant’s energy data from ERP, IoT sensors, and the manufacturing execution system to identify the most energy-intensive processes, showcased through an energy-monitoring dashboard.
Targeted prioritization: The analysis highlighted two key hotspots – reactors and industrial drying ovens – accounting for 80% of the plant's energy use.
Agile collaboration: We implemented an agile methodology, focusing on quick-win solutions through collaborative strategy development, weekly stand-ups, and planning sessions. This enabled rapid, hardware-free initiatives.
Continuous monitoring: We tracked progress and gathered employee feedback during and after each initiative, allowing us to iteratively refine and improve the approach for sustained savings and efficiency.
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Impact
Our data-driven approach targeted the largest energy consumers, leading to a 12% reduction in gas and electricity consumption, saving over €2 million annually. Key measures included optimizing production planning to reduce dryer use, fixing steam leaks, and improving operator procedures. Agile methodologies enabled rapid execution, avoiding long lead times and focusing on high-impact projects. These efforts reduced costs, improved efficiency, and helped the company enhance operational performance and sustainability.
