Premier Limpet – turning visibility into energy savings

Premier Limpet, a UK manufacturer producing more than 49 million square metres of printed tape each year with 38 printing machines, wanted to reduce energy costs across their two factories. By improving heating control and visibility, we helped them achieve up to 54% monthly energy savings and a 34% reduction overall.

Industry

Manufacturing

Primary Heating

Warm air blowers

Key goals

Cost savings

34 %

Savings delivered

Number of sites

Context

Premier Limpet were looking for ways to cut energy costs across their group as gas prices rose and contracts approached renewal.

At the Stevenage site, heating was managed locally by two floor-mounted warm air blowers and an oil boiler. Each unit was controlled by a basic smart timer with no central coordination or site-wide visibility.

There were no temperature sensors in the heated zones, no link to roller shutter doors, and no way to monitor heater performance or identify energy waste. The group had clear goals to reduce energy use but needed a plan or the tools to make it happen.

Solution

We began by installing an energy control system that created a single point of control for all heating equipment at the site. The system could be managed locally or remotely from any internet-connected device, giving full oversight of heating activity.

Each zone was fitted with a temperature sensor to measure and regulate heat distribution accurately. An external sensor on the north-facing wall allowed for weather-based adjustments, helping the system adapt automatically to outdoor conditions.

We also introduced self-learning start/stop optimisation to fine-tune pre-heat and shut-down times, ensuring energy was used efficiently without affecting comfort. Residual heat circulation was enabled to make use of stored warmth, and door sensors were added near shutter doors to automatically pause heating when doors were left open.

Impact

The result was a site-wide heating system that could finally be monitored, adjusted, and optimised in real time.

Our analysis forecasted a 25% reduction in energy use. After a year of operation, the data confirmed a 34% overall saving, with monthly reductions peaking at 54%.

The system has given Premier Limpet both the control and the visibility needed to manage energy more effectively across their operations.