Wiltshire manufacturer achieves carbon reduction target

The Client

Manuli Packaging are the largest stretch film producers in the world.  Having diversified into bubble production at their Wiltshire site in the mid-90s, followed by moving into packaging tape, their continuing growth now make Manuli Packaging one of the leading distributors of all film and tape products.

Manuli Packaging were struggling to meet their obligations under the Carbon Reduction Commitment (CRC) Energy Efficiency Scheme and turned to SMARTech energy for help.

Opportunities Identified – 35% Energy Reduction

SMARTech energy’s recommendations has enabled Manuli Packaging to embark upon a programme to achieve a 35% reduction in their energy consumption with a one year pay back period and a 148 tonne reduction in carbon emissions.  The opportunities identified and the application savings included:carbon-reduction-packaging-company

  • LED lighting upgrade – 86.4%
  • Motor optimisation – 35.1%
  • SMART air conditioning energy savers – 20%
  • Baseload reduction – 20%
  • Thermal insulation – 7%
  • Gas savers – 7.5%

How we helped

SMARTech energy installed Eniscope energy monitoring system at Manuli Packaging’s main production site in Wiltshire to generate minute by minute, real time analytics on energy usage and quality.  Our in-house ESOS approved assessors also carried out an in-depth audit of the site.  Combining the analytics from the energy monitoring with the data from the audits, we were able to understand HOW, WHEN and WHERE energy was being used and most importantly wasted.

From the analysis of the total site load we identified that the main bubble wrap production machine and its ancillary components accounted for 61% of the site’s energy consumption. In-depth monitoring of this machinery was then carried out to understand the profile of energy consumption and wastage of this machinery.

SMARTech energy consultants used the data collected to produce an energy reduction plan for Manuli Packaging.  This plan identified opportunities to reduce energy consumption by 35% at the site with a one year payback on investment, reducing carbon emissions by 148 tonnes per year.  This far exceeded Manuli Packaging’s commitments under the CRC Energy Efficiency Scheme.

Can we help you?

Our case study on SMARTech energy’s work with Manuli Packaging tells the story about how we helped reduce their energy consumption in more depth. If you would like to reduce energy waste, boost profits and cut carbon emissions then why not contact us to find out more about our Energy Management Surveys. As a Carbon Trust Accredited Supplier, we can also help most business access a 30% capital grant (up to a limit of £10,000) towards the cost of energy saving projects. Please contact us through our website or call us on 01225 635660.