Background
A long-established metal fabrication facility in Ireland, with over four decades of experience, specialises in designing, manufacturing, and installing bespoke metalwork solutions for the pharmaceutical, food, healthcare, and commercial sectors. Its 4,000 square metre campus includes stainless steel fabrication units, cleanroom furniture production, surface treatment facilities, and chemical cleaning centres.
The site employs around 60 people and operates five days a week, using electricity, heating oil, and diesel as its main energy sources. Systems on site include compressed air, HVAC, extraction fans, laser machinery, and process ovens—all contributing to significant energy demands.
The Challenge
The client wanted to better understand how energy was being consumed across their operations and identify opportunities to reduce costs and emissions without disrupting production.
Key drivers included:
- Rising energy costs affecting operating margins.
- Growing corporate targets for carbon reduction.
- Concerns over indoor air quality from diesel heaters.
The goal was to carry out a systematic energy audit, following the ISO 50002 framework, to identify practical, cost-effective, and health-conscious solutions.
The Audit Approach
The audit combined data analysis with a detailed on-site survey. Energy consumption was mapped across major systems, including lighting, compressed air, HVAC, and production equipment such as laser cutting machines and chemical process tanks.
Through this analysis, three main strategies were developed to deliver short-term savings and long-term sustainability benefits.
Strategy 1: Low Complexity, High Impact Measures
This strategy prioritised actions that could quickly deliver measurable results with limited investment or operational interruption.
Key recommendations included:
- LED Lighting Upgrade: Replacing 250 fluorescent fittings with high-efficiency LED alternatives, targeting a 62% reduction in lighting energy use.
- Energy Metering: Installing 12 sub-meters to improve visibility of energy consumption and enable data-driven management.
- 100 kW Rooftop Solar PV System: Generating on-site renewable electricity to reduce dependency on the national grid.
Results:
- Estimated annual savings: €47,445
- Carbon reduction: 60 tonnes of CO2 per year
- Simple payback: 2.9 years
Strategy 2: Health-Driven Decarbonisation
To improve air quality and reduce fuel emissions, diesel-powered mobile heaters were recommended for replacement with electric equivalents. Although this measure introduced a net annual cost, it offered meaningful benefits for occupational health, reducing workers’ exposure to diesel combustion gases indoors.
This initiative highlighted how decarbonisation can support both environmental performance and employee wellbeing.
Strategy 3: Green Electricity Procurement
The audit also evaluated the potential shift to certified green electricity. This measure would eliminate the site’s electricity-related emissions, reducing approximately 239 tonnes of CO2 annually. While it increased yearly energy costs, it aligned strongly with the company’s sustainability and corporate climate goals.
The Outcome
The audit provided the client with a clear roadmap for energy and carbon reduction, balancing financial, environmental, and health gains. By implementing these strategies, the company positioned itself as a sustainability leader within its industry—reducing operational costs, enhancing staff wellbeing, and contributing to long-term decarbonisation objectives.
