OP Chocolate

Industry: Food manufacturing

Service: Energy efficiency, energy purchasing, invoice validation and Climate Change Agreement management

Result: Circa £28,000 saving on gas

About OP Chocolate

OP Chocolate is a leading manufacturer of chocolate and wafer products, supplying major retail chains across the UK and overseas. Production, at its 16,000m² site in Merthyr Tydfil, takes place 16 hours a day, six days a week and processes include the production of wafers in ovens, chocolate coating of wafers, caramel manufacture, moulding of chocolate bars and end-of-line finished product packing.

The project brief

Innovative Energy Consultancy (IEC) was originally appointed by the Carbon Trust to help OP Chocolate to reduce its energy use. The company is subject to the CCA and had a target to reduce on-site energy consumption by 13.3%. This was achieved by 2010, and energy consumption has continued to fall against production since then.

The solution

First, IEC developed an energy action plan to motivate staff to reduce energy consumption, as well as make small investments to improve existing machinery. Next, IEC undertook detailed analysis to explore the most effective energy reduction measures. Sub-metering systems were introduced on all major equipment and the subsequent data analysis led to decisions to make improvements in air conditioning controls, heating, compressed air systems and pipe work insulation. When Carbon Trust funding came to an end, the company had saved a significant sum but continued to work with IEC to reduce energy use further still. IEC conduct monthly site visits to monitor energy use and implement efficiency programmes.

Key programmes include:

• monthly energy team meetings to keep energy efficiency on the agenda for the workforce
• a more proactive approach among staff to highlight efficiency issues
• isolation and removal of unused pipework, while improved insulation, plus new heating and lighting controls, have been introduced throughout
• purchasing of the client’s gas and electricity, validating the energy invoices and ensuring targets under the CCA scheme are met, so a rebate can be claimed on the tax element of energy bills in return for achieving energy reduction targets.

“We’ve worked with IEC for a number of years now, so they really do understand our business and continually help us to find ways to reduce energy consumption. Their work has made an enormous difference to our business. The monthly report and graphs produced against targets set at the beginning of each year enables the energy team to target projects that will deliver the necessary savings. The formation and management of the energy team keeps the issue on our agenda and ensures everyone in the company knows they have a part to play.

“Most initiatives have involved process improvements at relatively little cost. Where investment has been required it has been backed up by a detailed business case which tells us what cost saving we’ll achieve over what period of time. This has enabled us to make good decisions for the long-term, reducing our cost and our impact on the environment.”

Alan Barker, site services manager, OP Chocolate