Eco Insight energy monitoring identifies £42,000 cost saving for UK manufacturer

2 Minute Read

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The Challenge

Hyperbat, one of the UK’s largest manufacturers of high-performance electric vehicle battery packs, had energy-intensive assembly operations that, with rising energy costs, were growing concern for the business. 

With no real-time insight into energy consumption, usage patterns, equipment or building efficiency, the Hyperbat team was unable to assess current energy usage, identify areas of wastage, or take targeted actions to optimise energy usage and efficiency.

Energy efficiency is a major challenge for UK industry. According to the Carbon Trust, industry is responsible for 17% of the UK’s total energy use, most of which results from manufacturing. 

The Solution

Hyperbat implemented Eco Insight, a Unipart energy-monitoring product, into its battery assembly operations in order to:

  • Access real-time data and identify high-consumption equipment 
  • Quickly identify trends and anomalies through bespoke dashboards   
  • Use data-driven recommendations to optimise energy use, including scheduling production during off-peak hours or implementing energy-efficient equipment upgrades 
  • Engage employees in tangible ways to support energy-saving practices that save time, energy, and money.

£42,000

Identified cost saving

The Impact

The implementation of Eco Insight resulted in:

  • £10,858 delivered cost saving over a 12-month period
  • 35,028 kWh energy consumption reduction over a 12-month period
  • A further £32,000 of cost savings from 153,300 kWh of energy efficiencies identified as part of an ongoing sustainability plan for the business.
Eco Insight enabled Hyperbat to identify disproportionately-high energy costs being driven by an needlessly narrow temperature threshold inside a climate controlled area of our operation in use 24/7.

“Real-time data visualisation enabled us to quickly identify that high energy consumption was being driven by the system continually heating or cooling to maintain a -/+ 2°C temperature tolerance.

“Live EV batteries and cells do not need to be controlled to this level so we were able to extend the temperature to a 2-5°C variance which enabled the temperature in the room to fluctuate more, within the specific thresholds for stored components, significantly reducing the frequent and costly intervention of the climate control system.

Paul Day, Safety, Health & Environment & Production Lead at Hyperbat
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