Lowering emissions through energy efficiency, self-generation and monitoring

Warren Services are a precision engineering company, with two factories in Norfolk that make electro-mechanical, pneumatic and hydraulic machinery, and architectural structures.

Managing director William Bridgeman’s passion and in-house research has driven their decarbonisation strategy to reduce their Scope 1 and 2 emissions, enabling them to become carbon-neutral by the end of 2023, before progressing to net zero.

Warren has set benchmarks and identified areas to improve upon, by measuring their emissions for the last 8 years, along with monthly waste reports, half-hourly energy consumption data and real-time solar generation.

A range of energy efficiency and self-generation measures. 

Solar power has been key to their operations and produces all the power for one site and 30% of the energy used on the other (this will rise to 50% with additional panels). Seasonality presents a challenge, but they are exploring battery installation which may allow them to become completely off-grid for 4 or 5 months of the year. 

To drive up their factories’ energy performance they installed extra insulation, light sensors, thermostats, draft reduction measures (faster doors and door closure monitoring), air source heat pumps, and LED lighting. To decarbonise their process, which uses gas ovens, Warren are exploring high-temperature heat pumps. A new laser now uses 50% less energy than the previous one, and sensors provide real-time energy use monitoring of machinery, allowing for optimisation.

Outcomes

Emissions by unit of production decreased by 75% over the 8 years to 2023. Despite the cost, it has secured substantial reductions to their energy bills, solar has paid for itself and generates a ‘reasonable’ pay back. Importantly, it has boosted their reputation and helped secure contracts, such as a £2m deal to supply tree guards, where sustainability was a key factor in the award.