Multi-site manufacturing business identifies £90,000 cost savings using EI.

Multi-site manufacturing business identifies £90,000 cost savings using EI.

17th December 2025 | 2 min read

The Challenge

A multi-site component manufacturer operating high-load production equipment faced rising energy costs that were putting pressure on operational margins.

With ageing machinery, variable shift patterns and limited real-time insight into asset performance, the business required a solution that could:

  • Reduce energy waste without disrupting production
  • Provide rapid, measurable savings within the first year
  • Deliver visibility for leadership, finance, operations and maintenance
  • Retrofit quickly and easily across existing machinery, avoiding significant capital expenditure.

Like many SME manufacturers, they needed control, not just data, and clear insight into where energy waste was occurring across their curing, painting and composite processing lines.

The Solution

EI. Energy Control System was deployed across 41 of the business’s highest-consumption assets, including extraction systems, ovens, compressors and the primer and paint lines across two manufacturing facilities.

The deployment was designed to be low-disruption and insight-led:

  • Non-invasive installation in less than 48 hours ensured production continued with no downtime
  • A structured benchmarking period established accurate energy baselines for each asset
  • Cross-functional collaboration brought together the Finance lead, Operations managers and EI. Energy Gurus to interpret real-time data and prioritise high-impact actions
  • AI-driven analytics highlighted inefficiencies during non-production periods across a two-shift, four-day manufacturing cycle

From day one, EI. delivered active energy control, not just visibility, enabling the business to pinpoint waste and act instantly. Within 24 hours, operational leaders were identifying inefficiencies, understanding root causes and making real-time interventions.

The Impact

Within six months, EI. delivered £70k in realised energy savings, directly protecting site margins and strengthening the business case for further optimisation that identified a additional £20k saving.

Key outcomes included:

  • Immediate visibility across all functions. For the first time, leadership, finance, operations and maintenance shared a single, real-time view of energy performance across both sites, enabling swift process and behavioural changes
  • Significant reduction in hidden out-of-hours consumption, particularly on large extraction and process equipment
  • Predictive alerts connected maintenance and operations, reducing downtime risks before they escalated
  • Prioritisation of high-risk, high-cost assets, supporting data-led maintenance planning and reducing operational risk
  • A rapid ROI that exceeded expectations and created confidence in further investment in energy and operational improvements.

By moving from passive energy monitoring to real-time, actionable control, the manufacturer gained the intelligence needed to cut waste, protect working capital and improve operational resilience, without adding resource or disrupting production.

Unlock real-time energy insights to drive operational savings.