Brockhouse Group, a long-standing West Midlands based manufacturer, has achieved significant savings after implementing energy efficiency measures through the Business Energy Advice Service (BEAS) programme. As an energy-intensive business, Brockhouse faced rising energy costs that threatened its operations. By participating in the programme, the company identified key areas for improvement, leading to potential annual savings of £30,000, reduced energy consumption, and a lower carbon footprint.

Company Overview

Established in 1885, Brockhouse Group is a historic manufacturing business based in West Bromwich. The company specialises in closed die hammer and upset forgings for various industries. With energy-intensive operations that consume over 12 million kWh annually, energy has become the company’s third-largest expense after steel and labour. As energy costs continue to rise, the viability of its operations has been increasingly impacted.

Brockhouse Group recognised the need to reduce its energy consumption and mitigate the potential financial risks of future price hikes. Eager to find cost-effective and sustainable solutions, the company joined the Business Energy Advice Service (BEAS) programme, provided by Business Growth West Midlands. This initiative helps businesses identify energy-saving opportunities while also assisting in meeting decarbonisation goals.

Energy Assessment Findings

The energy assessment conducted through BEAS programme delivery partner, ProEnviro, revealed several inefficiencies in Brockhouse’s processes. Key findings included:

• Compressed Air System Leaks: The pneumatic systems were found to have multiple leaks, causing high energy waste.
• Inefficient Compressor Operations: Brockhouse’s compressors were operating inefficiently, contributing to excess energy consumption.
• Missed Monitoring Opportunities: Key equipment was not covered by the company’s energy monitoring system, limiting their ability to track and manage energy use.  
• Waste Heat Recovery Potential: Significant opportunities were identified for waste heat recovery, which could further reduce energy usage.

Implementation and Impact

Based on the findings, Brockhouse has undertaken several projects to optimise its energy usage:

• Linking and optimising the two compressed air systems
• Fixing compressed air leaks
• Extending energy monitoring to key equipment
• Installing waste heat recovery technologies

These measures are expected to result in annual savings of 585,700 kWh of energy, a reduction of 112 tonnes of Carbon, and a potential £30,000 cut in energy costs.

A Positive Outlook for the Future

Steve Walters, Director and Owner of Brockhouse Group, spoke highly of the programme’s impact on the business: “The programme is a fantastic opportunity to get independent advice on the best options for energy and cost reduction for your business. It has provided us with a clear path to making our operations more sustainable and efficient.”

By implementing these energy-saving strategies, Brockhouse is not only reducing costs but also ensuring long-term sustainability in a competitive and energy-reliant industry.

Learn more about the Business Energy Advice Service and register here - www.businessgrowthwestmidlands.org.uk/beas