Why did Bellurgan Precision Engineering Ltd. get an energy audit?
Manufacturing firm Bellurgan Precision applied for SEAI's Support Scheme for Energy Audits (SSEA) to meet one of their sustainability goals. Robert Caldwell, operations manager, explains why.
Bellurgan Precision Engineering are a manufacturer of precision machined parts and sub-components for the medical device and aerospace industries. The company was founded in 1978 by Bernard Carroll and has expanded over the years to where we now operate out of a 50,000 Sq ft facility and employ circa 100 people. Bellurgan Precision operates 24/7 shift patterns and have 47 machining centres with a mix of turning and milling capabilities. The company is based in Dundalk, County Louth.
Strategic motivation and SSEA audit
What were the key sustainability goals that prompted Bellurgan Precision to prioritise an energy audit for 2022–2023?
We had a goal of understanding our baseline energy use on site so that we could make data driven decisions that when implemented would be very clear to see when measured against our baselines.
What were your expectations going into the energy audit, and how did the actual process compare?
Again, we were expecting to have the hard data that would make prioritising projects easier, and also hopeful that a few gems would be uncovered. The audit did not disappoint, it provided us with clear baselines, targeted projects that could provide trackable results and a register of opportunities that would allow us to plan projects for in to the future so as to build on our improvements.
What were the most surprising or valuable insights uncovered during the audit?
That we potentially had the capability in waste heat to heat our factory year round.
Solar project implementation
Has the solar array delivered the expected 140,000 kWh per year? What results are you seeing?
Yes, we are averaging 140K kWh per year.
How has the solar installation affected day to day operations, especially given your 24/7 production schedule?
It has had no impact on our day to day operations as such. It provides on average 12-15% of our overall energy usage.
Heat recovery and additional measures
What benefits have you experienced from the heat recovery system that was scheduled for completion in 2023?
Since the implementation of our heat recovery system, we have eliminated the use of liquefied petroleum gas (LPG) on site.
How did earlier measures like LED lighting and sensors prepare the ground for larger projects?
I think it helped identify the low hanging fruit and sow the seeds of sustainability projects for Bellurgan, and us focussing on our energy usage.
Results
Which projects have shown the strongest return on investment so far?
In terms of energy usage, the solar installation has had the biggest impact. With energy costs at all time highs, it makes complete sense to focus on the biggest energy costs onsite.
Have you noticed changes in staff behaviour or attitudes toward sustainability since implementing the audit recommendations?
There has definitely been more of an awareness towards our energy use. The heat recovery project has sparked an interest in staff as to what’s possible.
Looking ahead
What additional energy or sustainability projects are now on your roadmap?
We have additionally conducted a process review of our waste water and waste chemical handling processes and made some great improvements. We have implemented a biodiversity area within our grounds to encourage wildlife. Also due to our locality to the coast we actively partake in beach clean-ups.
What advice would you give other manufacturing firms considering applying for SSEA?
The biggest advice I would give is to “Follow the process”. It takes time to gather baseline data but by starting with the energy audit, identifying the register of opportunities, and tackling the biggest bang for your buck projects it helps gather momentum and prove ROI for sustainability projects. The process is laid out as it is for a reason and by following the steps you get to see measurable improvements on your baselines. It helps to avoid the ad hoc approach to improvement.
Easy wins for SMEs
SEAI has a new, integrated suite of rapid approval grants, designed specifically with SMEs in mind. These financial supports for energy audits, insulation upgrades, heating and cooling upgrades, solar PV, among other upgrades, bring clarity and simplicity for SMEs to choose measures in any order that suit individual budgets, energy and building requirements.
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