Client
GAMO Outdoors
Scope
Implementation of an energy efficiency strategy to reduce the cost across the industrial lines
Industrial plants generally have high energy bills, as they require a lot of resources. However, with high energy consumption comes the opportunity to achieve savings with smart energy management in manufacturing.
As an European leader in rifle manufacturing, GAMO’s project objective was to reduce energy expenditure. The strategy included implementing an organization-wide energy management system, establishing energy policies, circulating communication campaigns and training employees at all levels.
The initial goal was set at a 10% reduction of energy consumption. Given the company’s increased rate of production, cost per unit manufactured was a key indicator. GAMO was looking for transparent energy management to analyze the relationship between its consumption and production.
The company started with a detailed Energy Audit, supported by Spacewell Energy. GAMO, supported by our partner 3eX4, monitored the electrical consumption of their four industrial buildings, as well as the main sub-meter consumption.
Energy Savings Measures and Results Obtained
Thermal Process Management
Process standby hours were reduced to meet production needs, which resulted in a scheduled consumption reduction from 3:00 am to 8:00 pm.
Wastewater Treatment
GAMO invested €2000 to reduce water flow in the treatment system’s evaporator – the principal energy consumer – without compromising quality levels. Achieved reduction of 25% in wastewater treatment
Passive Consumption
Power consumption was reduced from 10kW to 3kW by detecting and eliminating almost all non-essential consumption during passive hours (nights, holidays and weekends) and improving company-wide energy awareness and behavior.
LED Lighting Installation and Assembly Hall Sensors
The GAMO assembly hall has a zone of non-stop use (24 hrs / 241 days a year) which was previously lit by 12 x 300W (3.6 kW) projectors. 3ex4 replaced the system with 12 LED x 100W (1.2kW) projectors which resulted in an immediate 66% saving. Light sensors were also installed to regulate the switching on and off of lights and set to take advantage of ambient lighting. The improvement reduced overall lighting time by 30%.
Overall Results by Production KPI
Energy performance per unit manufactured fell by 28% within two years.
The improvements implemented reduced GAMO’s cost per unit manufactured by 15%.
A total of fifteen energy saving measures and investments were applied, which together demonstrated an ROI of under a year. This revealed a tremendous opportunity for energy management in manufacturing sector to realize energy savings in a short period of time.
Total savings during the first two years exceeded €85,000. GAMO and 3ex4 together dynamically reduced energy consumption, increased the company’s competitiveness, and instilled an energy-savings culture across the organization.
“We managed to implement a company-wide energy efficiency protocol that enabled us to reduce energy costs by 20% annually, increasing our market competitiveness while involving the entire organization in our energy efficiency efforts.” Josep Centelles, Industrial Director GAMO Outdoor
