The Client
Farrell Ltd is a UK-based global manufacturer of rubber mixing machines that sells to all of the top 100 tyre manufacturers. The north of England business operates a large, ageing factory and required a reliable, flexible, energy-efficient heating solution to maintain comfortable working conditions and reduce energy waste.
The Problem
The factory’s heating system, installed in 2008, was no longer fit for purpose. Poor insulation and a clunky, outdated control interface meant heating had to be cranked up manually during cold spells, leading to significant energy wastage and high costs.
Beyond the cost and comfort concerns, their previous system lacked flexibility and was no longer compatible with modern operational needs. Looking ahead, Farrell Ltd wanted to future-proof their heating system with a tamper-proof, web-based solution.
The Solution
After a site visit and consultation, Clarke Controls installed a modern, web-based Energy Management System tailored to the site’s specific needs. The factory was split into 27 heating zones, each with its own programmable schedule and an easy-to-use “boost” function. Workers could now activate heat in their own areas without relying on a blanket approach.
The upgrade delivered:
- Web-based, tamper-free control
- Easy programming for site managers
- Flexible zoning to target only the areas in use
The Results
In just four months, the factory saved 280 kilowatt hours, translating into £28,000 in energy savings – enough to cover the full cost of the new system.
The new system not only reduced costs, thereby cutting emissions, but also improved working conditions, giving the team full zonal heating control and zero complaints from staff.
Client Quote
I’d recommend Clive and his team – they’re innovative, and they’ll work with you to understand and address the issues.”
“The results have been better than expected, and we have saved 280,000 kWh in 4 months and expect to save £50k off an annual bill of £300k. Why wouldn’t you take the opportunity if you could?
