Sheard Packaging – Intelligent heating controls that paid for itself in 3 months
With ArcSett’s energy controls, Sheard Packaging took control of its kerosene heating system, cut its exposure to spot-rate fuel costs and reduce its Scope 1 emissions – achieving a 28.5% drop in oil consumption and costs within 12 months.
28.5 %
Savings delivered
3
Month payback period
90 tonnes
Co2 saved
Context
Sheard Packaging is the UK’s leading independent corrugated solutions provider, offering bespoke design, logistics and machine system solutions. Founded in 1860, the company operates the UK’s largest independent corrugated plant.
As part of its wider ESG strategy, Sheard set a target to reduce Scope 1 and 2 emissions by 42% by 2030, supporting wider procurement and legislative requirements.
The site combines older and newer factory areas, with 11 kerosene-fuelled heaters providing heating across the facility. Basic time clocks and smart-com controllers were already in place, but there were no local temperature sensors to accurately monitor heat distribution. Heaters located near roller doors also had no energy-saving strategy built into their operation.
Because the site relied on kerosene, fuel was purchased at spot-rate prices, leaving heating costs exposed to market volatility. Sheard wanted to reduce this exposure and lower overall heating costs without compromising the minimum heating levels required for day-to-day operations.
Solution
ArcSett installed its energy control solution to bring the heating system under centralised, remote-access control, giving Sheard greater visibility and flexibility across all 11 heaters.
Each heating zone was fitted with a tamper-proof outstation and internal temperature sensor, allowing the system to monitor conditions and adjust heating to match the needs of each area.
Door sensors were linked to heaters located near roller doors, helping reduce heat loss and wasted energy whenever doors were opened. An external temperature sensor also enabled weather compensation to optimise heating performance.
Role-based access controls were introduced so only authorised users could change settings, while built-in strategies including pre-heat and end-time optimisation created further opportunities to reduce oil consumption.
Impact
A 12-month fuel analysis, carried out by ArcSett after installation, showed that Sheard Packaging had cut oil consumption by 28.5% once adjusted for degree days – beating ArcSett’s forecast of 25%. This saved 57,776 litres of oil and 90 tonnes of CO2 over the 12 months.
The solution also delivered over £70K in annual cost savings and paid for itself in just 3 months, against ArcSett’s original forecast of 11.
These results have moved Sheard closer to its Scope 1 and 2 emissions targets, while giving the business much greater control over oil price fluctuations by cutting its overall consumption.
Get in touch
Ready to power possibility, together?