Company Profile Summary
Type: Medium-sized manufacturing company (Ireland)
Energy Sources: Electricity & Natural Gas
Energy Intensity: Energy costs less than 30% of production costs
Main Energy Uses
• Boiler (process and space heating)
• Lighting
• Heat pump
• Electricity generator
• Air compressor
• Material handling equipment
• Cutting machines (laser, oxyfuel, plasma, waterjet)
• Press brakes
• Drill press & milling machines
Energy Management
• No dedicated energy manager
• No formal energy policy
• External energy audit completed (2023)
Energy Efficiency Actions Taken and Implemented ECMs
The company implemented most of the low/medium-cost recommendations from the 2023 audit:
• LED lighting installation
• Other high-efficiency lighting upgrades
• Lighting controls (occupancy sensors, daylight sensors, timers, dimmers)
• Heating/cooling controls optimization (setpoints, schedules)
• Variable Speed Drives (some installed) / High-efficiency motors
• Replacement of old HVAC/boiler/heat pump systems
• Solar PV installation
• Building envelope upgrades (windows, doors, glazing)
• High-efficiency chiller installation
• Automation for scheduling & process control
Funding sources used: ESCO assistance + SEAI EXEED grant.
Energy Efficiency Actions Not Yet Implemented
The remaining audit recommendations not implemented due to high investment cost are:
1. Further upgraded heating/cooling controls
2. Additional variable speed drives or high-efficiency motors
3. Expansion of Solar PV
Barrier: Lack of internal capital investment.
Drivers for Energy Efficiency Improvement
• Reduction in energy use and costs
• Government requirements to improve efficiency and cut emissions
• Ageing / inefficient equipment
• Employee comfort & indoor environment quality
• Green corporate image & sustainability branding
• Government grants and financial incentives
Services Expected from Energy Consultant
1. Technical assessment of energy consumption
2. Identification of additional energy and cost-saving opportunities
3. Cost-benefit and financial analysis of measures (ROI, payback)
4. Support in accessing funding and grants
5. Ongoing monitoring and performance improvement
Key Recommendations for the Company
The company’s next steps should focus on building a structured, long-term energy management approach while prioritizing further technical improvements with strong financial and environmental returns. The first step is to establish a basic internal energy management framework by appointing an Energy Manager, a designated staff member responsible for monitoring energy use, coordinating efficiency projects, and maintaining communication with external consultants or agencies. Developing a short but clear Energy Policy will help formalise the company’s commitment to reducing energy consumption, improving equipment efficiency, and cutting carbon emissions. The company should introduce energy monitoring and targeting for its main systems, including boilers, compressors, and major production machinery. This will allow for better visibility of energy performance, quicker detection of inefficiencies, and more data-driven decision-making.
Further engaging with the Audit Plus energy consultant or ESCO (Energy Service Company) on a long-term basis will provide valuable technical and financial expertise. A consultant can conduct a deeper analysis of energy use patterns, identify process-specific energy saving opportunities, and carry out detailed cost–benefit and payback analyses for each measure. An ESCO partnership could also offer performance-based contracting, where energy savings fund the investment costs, thus overcoming the company’s current barrier of limited capital.
From a technical perspective, the company should prioritise high-impact measures such as installing additional variable speed drives (VSDs) and high-efficiency motors on pumps, fans, and compressors to reduce electrical demand and improve process control. The expansion of the existing solar PV system represents another strategic investment, helping to offset electricity costs and reduce exposure to energy price fluctuations while enhancing the company’s sustainability image. Implementing advanced heating and cooling controls, such as programmable thermostats and digital building management systems, will further optimise comfort and system efficiency, particularly in manufacturing and office areas.
Finally, the company should actively pursue available financial supports from national and EU programmes. Funding schemes such as the SEAI EXEED grant, the Accelerated Capital Allowance (ACA) tax incentive, and the Non-Domestic Microgen Grant can significantly reduce payback periods for capital-intensive projects.
The implementation of these recommendations will help the company to strengthen its energy management capabilities, lower operational costs, reduce carbon emissions, and position itself as a leader in sustainable manufacturing within Ireland.
Potential Energy and Cost Savings
If the remaining recommended energy efficiency measures are implemented, the company could achieve total energy savings of approximately 15–25% compared to current consumption levels.
The largest opportunity lies in the installation of additional variable speed drives (VSDs) and high-efficiency motors on pumps, fans, and compressors. These systems typically account for a substantial portion of total electrical consumption, and applying VSDs can reduce motor energy use by 20–40%, translating to an overall site-wide electricity reduction of approximately 5–10%. Implementing advanced heating and cooling control systems, including programmable thermostats, digital timers, and enhanced automation, can further reduce thermal energy demand by 3–5% through more precise temperature regulation, reduced operating hours, and minimised energy waste. Expanding the company’s existing solar PV system also presents a significant opportunity, with the potential to offset 7–10% of total electricity consumption depending on available roof area, system size, and operational profile.