New Balance – Reducing energy waste and improving control across site operations
New Balance wanted to cut energy costs, reduce carbon emissions and improve temperature control across its facility. After installing our energy control system, we delivered a 33% energy saving, reduced carbon emissions by 23 tonnes and made the site easier to manage day to day.
33 %
Savings delivered
23
Tonnes of CO2 saved
Context
New Balance designs and manufactures sports clothing and accessories that empower people through sport and craftsmanship. As part of their commitment to positive change and sustainability, they wanted to make their own operations more efficient and environmentally responsible.
Rising gas costs had increased annual spending by more than £18,000, and staff had reported inconsistent temperatures across the site. The site manager also had to walk through the factory to manually adjust the heating, wasting time and reducing control over energy use.
During our site survey, we found that heaters were grouped inefficiently, fans and coolers occasionally worked against the heating system, and shutter doors were not linked to heating controls, leading to heat loss. Some staff were able to override local heating settings, which meant systems were often left running unnecessarily.
The site included multiple radiant tubes and suspended warm air blowers, but no central control or monitoring system to manage them effectively.
Solution
We installed an energy control system to integrate all heaters and enable full visibility and control of energy use. Each heater was connected to the system for individual zoning and performance optimisation.
Local control panels were relocated and secured with PIN-protected access, ensuring only authorised staff could adjust settings or override pre-set schedules. The new system also offered remote access, allowing managers to monitor and adjust site heating from any internet-connected device.
Energy-saving strategies were enabled across all zones, including residual heat circulation, which keeps fans running after burners switch off to maintain warmth using existing heat, and weather compensation via an external sensor to adjust performance based on outdoor conditions.
Door switches were installed and linked to heaters so that heating automatically paused when nearby shutter doors were left open, encouraging staff to close doors and preventing unnecessary gas consumption.
Impact
The installation provided full control and visibility across the site, allowing heating to be managed efficiently and consistently for the first time. It also saved staff significant time by removing the need for manual checks and local adjustments.
We initially forecasted a 25% energy saving with a 14-month payback, equivalent to around 18 tonnes of carbon savings. After the first year, fuel analysis confirmed a 33% reduction in energy use, saving approximately 23 tonnes of carbon.
The result was a more comfortable, energy-efficient working environment that aligned with New Balance’s wider sustainability goals while delivering clear operational and financial benefits.
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