Company Overview
• Sector: Healthcare (medical packaging)
• Size: Medium enterprise
• Energy Sources: Electricity, natural gas, renewable energy
• Annual Consumption: 2,775,057 kWh electricity; €108,000 gas
• Energy Costs: 50–70% of total production costs → energy-intensive operations
• Energy Management: Part-time energy manager, no formal energy policy
Key Energy Consumers
• Boilers, HVAC systems (7 air handling units), chiller, cogeneration unit
• Compressors (5 large units), production line equipment (packaging machines, conveyors, shredders, crushers)
• Material handling, weightlifting machines, overhead cranes
• Lighting
Historical Audit Findings
• 2016 Audit:
Implemented: LED lighting, partial heating/cooling control upgrades, some high-efficiency motors and VSDs
Not implemented: Full HVAC controls, VSDs on pumps/fans, major heating/cooling system upgrades
Barriers: Limited capital, long payback periods, low knowledge of available subsidies, time/resource constraints
• 2025 Audit Plus Audit:
Provided independent, up-to-date assessment of energy consumption and system performance
Identified short- and long-term energy-saving opportunities, cost-benefit estimates, and potential funding support
Drivers for Energy Efficiency
• Reduction in energy consumption and costs
• Compliance with government mandates on carbon reduction
• Aging or low-efficiency equipment
• Customer demand and sustainability image
• Availability of free consultancy services
Key Recommendations for the Company
1. Technical & Operational Measures
The company should target its key energy-intensive areas to achieve measurable savings. For compressors, installing variable speed drives, optimizing pressure levels, repairing leaks, and recovering waste heat can reduce energy consumption by 15–25%. In HVAC and cleanroom systems, upgrading to smart controls, implementing variable air volume, and incorporating heat recovery technologies can lower electricity use by 10–30% while maintaining strict environmental standards. For boilers and thermal systems, replacing outdated units with high-efficiency condensing boilers or hybrid heat pumps can cut energy use by 10–20%, and optimizing the cogeneration system to better match electricity and heat loads can yield an additional 5–10% efficiency gain. Lighting systems should maintain LED technology and integrate occupancy sensors and automated controls, producing an estimated 5–10% reduction in energy consumption. These technical and operational measures are expected to deliver significant energy and cost savings while improving system reliability and performance.
2. Organizational & Behavioral Measures
• Develop a formal Energy Policy
• Assign clear energy management responsibilities and KPIs
• Conduct staff awareness training to encourage energy-conscious behavior
• Introduce routine energy monitoring and reporting dashboards
3. Financial & Funding Measures
• Identify European, national, and regional grants/subsidies to fund upgrades
• Prepare investment-grade proposals with ROI and payback analysis
• Consider phased implementation to match available budget and maximize impact
4. Long-Term Strategy
• Implement an Energy Management System (ISO 50001)
• Establish continuous monitoring, review, and performance improvement cycles
• Plan major upgrades (boiler/heat pump, HVAC, cogeneration) over 18–36 months
• Partner with energy consultants for technical support and funding guidance
Suggested implementation roadmap
The implementation of energy efficiency measures should follow a phased approach. Phase 1 (0–6 months) involves reviewing the 2025 Audit Plus findings, formalizing an energy policy, and identifying funding opportunities, providing a verified baseline and a funding-ready action plan. Phase 2 (6–18 months) focuses on implementing high-return measures, such as variable speed drives, HVAC control upgrades, and staff energy awareness training, delivering immediate energy and cost savings. Phase 3 (18–36 months) targets long-term upgrades, including replacement of boilers or heat pumps and optimization of the cogeneration system, resulting in significant energy efficiency improvements and carbon reduction. Phase 4 (ongoing) establishes continuous monitoring, periodic performance reviews, and ISO 50001 certification, ensuring sustained energy management, continuous improvement, and compliance with regulatory and sustainability goals.