PPG – Delivering Improved Efficiency and Consistent Manufacturing Conditions
Heating control optimisation across a multi-building paint manufacturing and logistics facility, delivering a 30% reduction in gas consumption while maintaining critical production temperatures.
30 %
Savings delivered
7
Months payback period
473 tonnes
Co2 saved
Context
PPG is a leading manufacturer of paints, coatings and specialty materials, supporting customers across a wide range of sectors.
At its Birstall facility, PPG operates across eight buildings with a mix of heating needs. The existing system relied on basic controllers and manual intervention, making it difficult to manage heating consistently across the site. The timers could not provide the accurate temperature control needed to support product quality.
With gas prices rising and PPG focused on its sustainability goals, the objective was clear: centralise control, reduce energy use, lower costs and maintain stable temperatures across critical manufacturing areas.
During our initial survey, we identified radiant tube heaters, warm air blowers and boilers across the site, along with multiple roller shutter doors in logistics areas and temperature-sensitive production spaces. These all needed coordinated control and better visibility to deliver meaningful savings.
Solution
ArcSett installed Energy Controls across the site, retrofitting the existing heating systems with accurate temperature sensors, communication units and central control equipment.
This gave PPG one point of control for all heating equipment, accessible both locally and remotely through any internet-connected device. We also installed door sensors near roller shutters, particularly in logistics areas, so heating could pause when doors opened and reduce wasted energy.
As several teams needed access to the system, ArcSett worked with PPG to create a user permissions matrix. Shift team leaders could manage their areas within agreed limits, while senior site managers kept overall control of time and temperature settings.
After installation, ArcSett provided quarterly savings analysis to track performance against the projected 25% savings. We also used data from the controls to recommend temperature and configuration changes that helped maximise savings. PPG invited ArcSett into senior manufacturing team meetings to share performance with the wider facilities and engineering teams. This helped site teams see the impact of better heating management and supported a consistent approach to using the controls.
Impact
Our 12-month review, using degree day analysis, showed a 30% reduction in gas consumption. This equated to 2.7 million kWh saved and 473 tonnes of CO₂ saved.
The project exceeded the original projected saving of 25% and achieved payback in just 7 months, ahead of the projected 18-month payback. The controls gave PPG the visibility and control they needed to reduce unnecessary heating hours, manage temperatures more accurately and maintain stable manufacturing conditions.
PPG Birstall also won an internal silver sustainability award, using the energy controls and savings analysis as evidence for its submission.
ArcSett is proud to have supported PPG with a project that delivered measurable savings, improved site control and contributed to its short and long-term sustainability goals.
Our experience with ArcSett has been exceptional, both from a system and service perspective. The heating management system is intuitive, user-friendly and continues to add value over time.
ArcSett supported us throughout the project, from building the business case through to managing a complex multi-building installation. Since implementation, we’ve achieved a 30% reduction in gas consumption across the site by eliminating unnecessary heating in unoccupied areas, reducing costs while supporting our sustainability objectives.
Overall, ArcSett has delivered an excellent solution backed by outstanding customer service and professional project management. I would highly recommend them to any organisation looking to improve energy efficiency, reduce costs, and gain greater control over their heating systems.
Rob Tolson,
Strategic Sourcing Specialist, PPG
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