Calculated approach to energy efficiency

Montupet UK supplies precision manufactured cast aluminium components to the global automotive manufacturing sector from six factory sites. The Belfast site, which has an annual turnover of approximately £70 million and employs in excess of 550 people, wanted to reduce energy costs, and to improve its environmental profile by reducing its carbon footprint.  

To address the issue of energy cost, Montupet identified that electric motors were the biggest target, as these consumed 70% of an annual electricity bill in the region of £3 million. With an on-going carbon reduction target of 3% per tonne of components sold it was decided that the issue of energy efficiency needed to be tackled in a way that would deliver measurable results both in terms of financial savings and carbon emissions.

ERIKS TCO (Total Cost of Ownership) Motor Calculator has enabled the Belfast site to significantly increase energy efficiency and achieve capital payback for all motors, which have been replaced or upgraded, within two years.  As a result of its experience with the motor calculator, Montupet is making increased use of the tool and planning to apply it group wide.

The motor calculator uses data relating to the current motor to calculate key statistics, such as annual running cost, carbon footprint, energy usage in kilowatt hours, and so on.  The user can then view the total cost of ownership for the year, or for fifteen years, or any period of years in between.  The results provided by the calculator will list and compare the cost of repairing and running the existing motor, replacing it with a standard IE2 motor, or replacing it with an energy-efficient IE3 motor.

Certain high usage critical applications were identified as 'Show Stoppers', for example a 90kW external extraction process fan. Using the motor calculator, Montupet was able to compare the annual running cost of the existing motors and the potential IE3 replacements, plus the amount of CO2 generated per annum .This data was then used to provide a justification report for upgrading the asset.  Once the replacement had been fitted, tests were undertaken to confirm that the information provided by the motor calculator was correct.

Montupet has so far replaced 15 motors with a new IE3 equivalent, achieving capital payback within two years. A further 25 are due for replacement during the coming months, which will complete phase one of what is now a major motor upgrade project to maximise energy efficiency.

In recognition of Montupet’s focus and determination to reduce carbon consumption, cut costs and increase operational efficiency ERIKS has presented the company with its prestigious Positive Energy Reduction Award.

"The ERIKS TCO Motor Calculator has provided robust and reliable information to enable our business to make the right energy saving decisions,” said Robert McKenzie of Montupet. "All the stakeholders within our business are fully committed to this project. Our senior management, purchasing department, maintenance teams and energy efficiency initiative team have embraced the work we have done.”

Jon Sansom from ERIKS added: "The secure website has already registered a high level of use, so it is obvious that Montupet has fully utilised the ERIKS TCO Motor Calculator and seen a real benefit. We have been more than happy to provide the on-going local support from our Belfast Service Centre and are working with them to aid Montupet in reducing its motor running costs.”