John Pointon & Sons operates the largest single-site rendering and recycling facility in the UK in Cheddleton, Staffordshire. The processes at this site use a large amount of gas and other utilities and the company was struggling with reliable metering. I/O modules that were being used for energy monitoring were failing due to the corrosive site environment, leading to poor data collection and regular unplanned downtime. Inadequate software also meant the company couldn’t make good use of the data that was being recorded or assess where energy savings could be made.
Endress+Hauser carried out an energy efficiency assessment and subsequently supplied a complete energy monitoring solution. As well as supplying T-mass, Prowirl, Promag and Promass flowmeters to monitor gas, water, steam and tallow (animal fat), Endress+Hauser installed a WirelessHART data collection system. Data is now collected from a WirelessHART SWG70 gateway and stored within an Endress+Hauser data logger. Every 30 minutes, the data is sent to the cloud-based eSight energy management system.
In later phases of the project, Endress+Hauser also supplied Deltabar differential pressure transmitters for odour abatement and a dissolved oxygen monitoring solution for the on-site water treatment plant.
Unlike some other manufacturers, Endress+Hauser was also able to offer consultancy services to support the company with their Energy Savings Opportunity Scheme (ESOS) assessment, which is compulsory for all large businesses, and helped it to achieve ISO 50001 accreditation for energy management.
The company exceeded its target of saving 5% gas and electricity in 2017, which equates to a cost saving of more than £400,000, and is hoping to achieve a further 2.5% reduction in 2018. The company was also able to achieve its ISO 50001 accreditation.
Paul Latham, Energy Manager at John Pointon & Sons, said: "We used to just pay the bill and that was it. Now we look at how the energy is being used and we can see trends. We use eSight to prepare a weekly report and the graphs make it easy to see if you’ve got an issue Main tallow Promass meter somewhere. Just recently we went sky high with our kilowatts per tonne and we were able to identify a problem with the valves on the cookers which meant the steam was being wasted. We probably wouldn’t have known about it before this system was installed. Now I know exactly where the problem is and we can get on top of it."