Tex Plastics Case Study
Tackling quadrupled utility rates and identifying rapid-payback industrial energy-efficiency avenues.
Introducing Tex
Tex Plastics, a UK plastic injection moulding manufacturer, was facing rapidly increasing energy costs, with its energy bills quadrupling over the previous three to four years. The company needed to reduce these escalating costs while improving operational efficiency and supporting its sustainability objectives.
The Challenges
Quadrupled Utility Bills
Massive macro-market tariff spikes rapidly threatened operational margins over a short 3-year timeline.
Moulding Cycle Waste
High-temperature injection moulding demands massive baseloads with no visibility into machine-level idle times.
Operational Blindspots
Facility managers relied on aggregate monthly utility invoices with no method to isolate inefficient moulding cells.
The IoTech Solution
Three Eniscope units, together with Virtual Energy Monitoring, were deployed across 15–20 key assets, providing real-time, site-wide visibility into energy consumption. This gave the engineering and management teams access to live data, enabling them to identify and act on energy inefficiencies.
- 01 Deep granular sub-metering on core plastic moulding machinery units.
- 02 Predictive machine analytics tracking optimal cycle power draws.
- 03 Management portal integration linking output metrics with physical units.
Key Outcomes
More Than 26% Energy Savings
Delivered a spectacular reduction in plastic manufacturing energy footprints.
£237,000 in Annualized Savings
A massive budget recovery enabling further capital re-investment back into the business.
3-Month Payback Timeline
Achieved complete project self-funding and breakeven inside ninety days.
Achieved complete project self-funding and breakeven inside ninety days.
Deep sub-metering on key injection moulding blocks giving live, granular feedback.
Live Engineering Portal
Gave direct floor-manager access to real-time machine efficiency performance analytics.
Carbon Compliance Foundation
Underpins carbon reporting with accurate, auditable, high-resolution empirical metrics.
Project Conclusion
The project demonstrates how real-time energy monitoring can help manufacturers identify inefficiencies, control rising energy costs, and turn consumption data into measurable financial and operational improvements.
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