Leading energy efficiency specialists, JRP Solutions, selected the McVitie’s manufacturing facility at Tollcross, Glasgow to participate in a collaborative project using an innovative new methodology and software tool called Energy Initiator®. The objective of the project was to identify how energy was being used across the business and more importantly how energy costs might be significantly reduced.
The McVitie’s plant at Tollcross, Glasgow produces approximately 40,000 tonnes of biscuit products per annum across twelve process lines consuming approximately £2m of energy each year.
It was clear from the outset that the site had little focus upon energy and had limited resources to effectively address energy related issues.
To gain a real insight into how energy was being used and where it was being wasted at the Tollcross site JRP used Energy Initiator® to investigate:
- Two representative process lines
- Eight individual assets
- Boiler house
- Common utilities (including gas, electricity, steam, compressed air)
Eighty improvement opportunities were identified, including specific capital projects, maintenance improvements and behavioural changes which would reduce the site’s energy consumption by more than £840k within three years reducing the site’s CO2 emissions by 117,000 te.
The typical payback for these improvement opportunities was just 1.4 years.
Key recommendations were made which included the development of a detailed Five Year Energy Plan, the prioritisation and implementation of improvement projects and a training programme designed to raise knowledge and awareness of energy throughout the business to effect cultural and behavioural change.
“Energy Initiator® was recently deployed at Tollcross and identified numerous practical wide ranging improvement opportunities that, predicated savings based on analytical findings, could reduce our energy costs by a staggering 41%.” – Stephen Marshall, Engineering Manager, McVitie’s
“With energy prices likely to continue to rise businesses should grasp opportunities like these as soon as they can.” – Paul Wedgwood, General Manager, Scotland, for the Carbon Trust