How Data Visualisation Saved One Manufacturer £100k
When manufacturers think about energy efficiency, the first ideas are often new equipment or large capital upgrades. What is less obvious is the value of simply being able to see what is happening in real time. One of our clients in the manufacturing sector recently saved more than £100,000 in a single year by putting energy data front and centre. Their story shows just how powerful energy monitoring savings can be.
Before the Dashboards: Working Without Clarity
This client operates several production sites across the UK. Like many manufacturers, they faced rising energy costs but had little visibility of where the money was going. Bills arrived once a month, covering entire facilities, and gave no breakdown of which processes were responsible. Managers suspected waste but had no proof and no way to make the case for investment.
Without reliable data, decisions were based on instinct rather than evidence. That made it difficult to build a strong business case for change.
Real-Time Dashboards in Action
Our first step was to install sub-meters across key areas of the production line and bring that information into a clear, accessible dashboard. The goal was not just to gather data, but to give plant managers, finance leads, and sustainability teams the same picture of what was happening day to day.
The difference was immediate. Within the first week, the dashboards showed that one production hall was using almost double the electricity of another despite producing the same output. They highlighted compressors running long after shifts had ended and revealed that machinery was drawing power during downtime. Old lighting left switched on after hours was another drain that had never been noticed before.
Turning Insight into Savings
Armed with this information, the client made a series of changes. Timers were adjusted, lighting was upgraded to LEDs, and tighter controls were introduced across the production line. Compressed air leaks were fixed quickly and cheaply, yet the savings they unlocked were substantial.
In the first year these measures delivered just over £100,000 in cost reductions. The compressed air work alone cost less than £5,000 but saved more than £25,000, paying for itself within a few months. Larger investments such as the LED upgrades had a payback period of under two years.
This was not just theory or a projection. The savings were visible in the dashboard week by week, proving to managers and the board that interventions were working. That visibility built confidence and encouraged further action.
The Carbon Benefit
Financial results were matched by environmental progress. The client avoided more than 250 tonnes of carbon emissions in the first year. For a sector under pressure to align with supply chain and investor expectations, this was a milestone. It also gave the business stronger footing in contract negotiations where sustainability credentials are increasingly scrutinised.
Lessons for Manufacturing
This experience highlights that energy dashboards are not only about reporting. They are a practical tool that allows manufacturers to:
Compare performance across multiple sites
Spot waste quickly and act before it becomes costly
Track the return on investment from upgrades with confidence
Report progress clearly to regulators, investors, and customers
For manufacturers where margins are tight, these insights can mean the difference between standing still and building a competitive edge.
Why This Matters Now
Energy costs remain unpredictable and carbon targets are no longer optional. Dashboards offer quick wins that do not require years of planning. They provide the evidence needed to build the case for larger changes, whether that is electrification, renewables, or more efficient equipment.
Final Thought
The £100,000 saved by this client is a clear reminder that good data leads to good decisions. Energy dashboards help manufacturers cut costs, reduce emissions, and strengthen their position in an increasingly demanding marketplace.
If you want to turn hidden waste into visible opportunity, our team is here to help.