From assumptions to facts and major energy savings
Fagerhult is one of Sweden's leading players in the development and manufacture of professional lighting. With a production area of over 43,000 m² and a large number of energy-intensive machines, energy consumption has always been a central issue. But previously, the level of detail required to understand where the electricity actually went was lacking.
“We thought we knew where our biggest energy consumption was – in the sheet metal shop and paint shop – but when we started measuring with DAZOQ Energy Intelligence (DAZOQ EI) we realized that we had only found about half of the consumption. The rest was a hidden energy thief that we needed to map,” says Christer Hansson, Maintenance Manager at Fagerhult.
CHALLENGE: ASSUMPTIONS INSTEAD OF FACTS
Just like many other manufacturing industries, Fagerhult had long relied on overall measurements and estimates. This gave a picture of total consumption, but did not provide the basis for making the right decisions or identifying the real energy guzzlers. The result was that some machines were running unnecessarily, that compressors and ventilation were running even though the premises were empty, and that investments were made without seriously considering energy consumption.
"Previously, we turned off machines without knowing what it did – it was mostly just a matter of routine. Without numbers, it is difficult to justify a change. Now we can show 'this is how it was before, this is how it is now' – and not only prove what we are actually saving, but also more easily motivate ourselves to maintain the change," says Anders Tedman, Industrialization Manager.
THE SOLUTION: MEASURING AT A DETAIL LEVEL WITH DAZOQ
When Fagerhult started using DAZOQ EI, they gained a whole new level of insight. By measuring at the machine level, they were able to quickly identify patterns and inefficiencies that had previously gone under the radar. This included everything from standby consumption to ventilation systems that were running at full capacity even when production was at a standstill.
Data visualization has also made employees more aware and engaged. On the shop floor, they can now see energy consumption in real time, which has changed behaviors and culture around energy.
"When we got DAZOQ's visualizations, it was an eye-opener for the entire organization. It became clear that we could actually influence our costs - just by shutting down, adjusting and following up," says Anders Tedman, Industrialization Manager.
RESULT: OVER 1.5 MILLION SEK IN SAVINGS
Tack vare kombinationen av smarta investeringar och bättre kontroll på befintliga system har Fagerhult redan sett stora resultat.
- Compressors and ventilation: With the help of DAZOQ EI, Fagerhult saw that these processes were running completely unnecessarily, when the premises were empty, but also that there were old inefficient solutions. Through correct scheduling and optimized control, they saved 650,000 SEK/year.
- Ventilation in the paint shop: Capacity adjustments reduced costs by 200,000 SEK/year.
- Machines on standby: By changing routines and turning off machines when not in use, 60,000 SEK/year can be saved.
In total, this means savings of nearly 1.0 million SEK each year – just during the first six months of the project.
A NEW WAY TO LOOK AT INVESTMENTS
In addition to the direct savings, DAZOQ has given Fagerhult new tools for making long-term decisions. When making investments, they now look not only at capacity, but also at energy consumption and how it affects the payback period.
"In the past, energy was rarely included in the decision-making process. Today, it is an obvious part of calculating the ROI of a new investment." If I want to make an investment of SEK 500,000 in a new oven, which can save us SEK 300,000 annually in energy costs, the payback period will be very short. Being able to show actual numbers makes it much easier to get investments approved,” says Dennis McCrady, Property Manager.
CONCLUSION
For Fagerhult, DAZOQ has become more than an analysis tool – it has laid the foundation for a new energy culture in the organization. By moving from assumptions to facts, they have unlocked major savings, gained better decision-making support and made the energy issue a natural part of both everyday life and strategy.
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