Compressing energy consumption

An energy audit by engineers from RDA One NorthEast has helped a County Durham manufacturer save £35,000 and tonnes of CO2 a year.

Specialists from the One NorthEast’s Energy Resource Efficiency (ERE) programme have been working at the Geka Manufacturing plant in Tanfield Lea, County Durham, for the past five months.

Following an energy audit of the plant, they identified many areas where Geka Manufacturing could make efficiency savings, bringing in Loughborough consultancy Air Technology to help refine production processes.

As a result of the training provided the company has cut its carbon emissions by around 300 tonnes per year, reduced energy bills by 20 per cent and will save the business over £35,000 a year.

Geka manufactures high quality cosmetics packaging for market leading brands using a process that involves receipt of raw materials, injection or blow-moulding, printing and final assembly.

Compressed air is an essential part of the process, and one of the largest users of electricity, accounting for almost 35 per cent of site usage. An Energy Diagnostic carried out by ERE engineers identified compressed air as one of the areas where significant energy savings could be made.

Unreliable compressors were replaced with a new system to reduce costs by £19,000 and support an increase in productivity by up to 30 per cent.