​Pressure Swing Absorption (PSA) Nitrogen Generators to utilise surplus capacity of existing air compressors produce 99.9% pure nitrogen at rate of 12 m3/h at the ratio of 3.8:1 to replace liquid nitrogen delivery from BOC for cost savings.

Replacement of a 20 years old 4 t/h 80% efficient boiler with 2 local high-efficiency and modulated ignition 98% efficient steam generators of 2 t/h each to meet heating demand for production.

Thermographic survey of steam supply and condensate return pipework for the whole site, energy losses estimation and insulation for reduction in energy consumption.

Recovery of IsoparM solvent from contaminated solution by liquid-solid separation through ATEX rated centrifuge machine to replace time consuming sedimentation and decanting process. 

Recovery of Rhodiasolv solvent from vessel cleaning waste by liquid-solid separation through vacuum distillation and reuse for cleaning.

Recycling of blowdown wastewater from cooling tower to maintain conductivity and deionisation plants during regeneration phase for general floor cleaning purpose.

Replacement of site standard lighting with LED lighting and intelligent light control system for automatic adjustment of luminosity through detection of operators in the area.

Auto shutdown system of conveyor belts and compressed air supply when production lines are not operational to save energy.

Reduction in cleaning water consumption by replacing water boil out of production vessels with high impact rotary jet washing system including high pressure pump.

Reduction in power consumption from chillers by installing induced draft cooling tower to utilise cold weather conditions when ambient temperature is below 20 degC for over 80% of the time of year and reduce the load from chillers.

Modification of Nitrogen blanketing system of Isocyanate feed vessel storage tank to eliminate the constant flow of inert gas and maintain required pressure to avoid moisture from atmosphere.

Flue Gas Heat Recovery System (FGHRC) from boiler gas flue to preheat cold water for boiler including plate heat exchanger and water temperature data loggers for estimation of heat recovery.

Reduction in the consumption of Nitrogen purge from reactor by installing Oxygen sensor in the vent route to indicate oxygen concentration and stop purge when it is below 1%.

30 meters deep borehole for ground water to reduce water bills.

Replacement of time consuming and inefficient suspended solids testing oven with rapid evaporation through halogen lamp moisture analyser.

Upgrade of blow moulding machines and silos installation for blending PCR material with virgin resin to produce bottles with 50% recycled material.

Installation of 565kW solar panels for £400k on warehouse roof with 30% internal rate of return per year, 105 tonnes CO2 savings per year and payback period of 3 years.