Bonaprene Case Study
Strengthening industrial sustainability and eliminating latent out-of-hours factory equipment waste.
Introducing Bonaprene
Bonaprene, a leading UK polyurethane manufacturer serving the industrial, automotive, and aeronautical sectors, wanted to reduce energy consumption and strengthen its sustainability performance without affecting production output. The factory was experiencing several areas of hidden energy waste, including heating equipment operating longer than required, machines running outside production hours, and energy-intensive equipment operating at full capacity despite changing production demand.
The Challenges
Out-of-Hours Running
Industrial curing ovens and heating cycles left active overnight and outside shifts due to lack of visibility.
High Idle baseloads
Inductive machinery idling during workflow changeovers creating silent, massive energy penalties.
Hype vs. Hard Data
Struggling to track exact per-machine return on sustainability investments without localized metering.
The IoTech Solution
Through a Best.Energy partner, Eniscope was installed across two production lines to provide real-time energy data and 24/7 analysis of individual machinery.
- 01 Asset-level monitoring of high-draw industrial curing ovens.
- 02 Scheduling optimizations mapping out shifts to match efficient energy rates.
- 03 Staff engagement tools showcasing live floor metrics to drive operational hygiene.
Key Outcomes
30% Energy Savings Identified
Immediate visual mapping showed massive, low-cost avenues for operational efficiency.
Over £20,000 Annual Savings
Significant reduction in overall manufacturing overhead translating to a healthier bottom line.
24/7 Machine-Level Analytics
Established discrete asset tracking across two primary heavy industrial production zones.
Real-Time Operational Mapping
Allowed plant operators to spot scheduling errors instantly on the live cloud portal.
Out-of-Hours Cleanup
Stopped multi-circuit overnight idling wastage by enforcing clear automated shut-offs.
5x Return on Investment
Ongoing savings verified at five times the cost of hardware and monitoring services.
Project Conclusion
By using granular energy data to improve operating schedules, equipment settings, and production processes, Bonaprene was able to identify and reduce unnecessary energy consumption.
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