GAMO Case Study • Sector: Industrial • Annual energy consumption: 2.500.000 kWh • Annual consumption: 350.000 € • Consolidated savings: 28%
enginyeria eficiència energètica
Why DEXMA? It’s
the
best
option
on
the
market. DEXCell Energy Manager is powerful, rapidly evolving and meets all our requirements. Robert Martínez, Consulting Partner 3ex4
GAMO reduced its savings performance by 28% in 2012, securing its competitiveness in the sector with the help of 3ex4 and the DEXCell Energy Manager.
Customer GAMO Outdoor has been manufacturing rifles, guns and bullets for 40 years. It is the European leader in the manufacture of air rifles and a world leader in the manufacture of high quality ammunition and carbines. Customers in over 80 countries count on its innovative technology, which results from continuous investment in new production processes that combine craftsmanship and technology.
Challenge GAMO’s project objective was to reduce energy expenditures by implementing an organization-wide energy management system, establishing energy policies, circulating communication campaigns and training employees at all levels. The initial goal was set at a 10% reduction. Given the company’s increased rate of production over the two previous years, it would need to set cost per unit manufactured as a key indicator, and be able to use its energy management tool to analyze the relationship between its consumption and this variable.
GAMO Case Study
Solution In late 2010, the company performed an energy audit, using the DEXCell Energy Manager to monitor the electrical consumption of its four industrial buildings, as well as monitoring its main sub-meter consumption during the beginning of 2011. 3ex4 and GAMO implemented numerous improvements between 2011 and 2013.
Results Taking 2010 consumption levels as a reference, the improvements implemented reduced GAMO’s cost per unit manufactured by 15% in 2011, and lowered the cost per unit by 28% in 2012. A total of fifteen energy management improvements and investments were applied between 2011 and 2012, which together demonstrated an ROI of under a year, revealing a tremendous opportunity for companies in the industrial sector to realize energy savings in a short period of time. Total savings during the first two years topped 85.000 €. GAMO and 3ex4 together dynamically reduced energy consumption, increased the company’s competitiveness, and instilled an energy-savings culture across the organization.
DEXMA
We managed to implement company-wide energy efficiency protocol that enabled us to reduce energy costs by 20% annually, increasing our market competitiveness while involving the entire organization in our energy efficiency efforts.
Josep Centelles, Industrial Director GAMO Outdoor
creates energy savings and management softwa-
equipment and SCADA/ BMS systems. The software
re solutions for a range of sectors including corporate, public
enables invoice management, real-time monitoring of
administration, the service sector, and the industrial and
energy consumption, remote meter reading, and visibility of
residential sectors. Its software is distributed through a
consumption of all energy subsystems.
network of partners that include utility companies, mainte-
DEXCell Energy Manager offers basic functionalities, such
nance firms, ESCOs, integration consultants, installation
as profile-specific dashboards, reporting and alerts, as well
companies, energy distributors and telecoms. The DEXCell
as more advanced features, such as benchmarking, detec-
Energy Manager is a 100% web-based energy management
tion of excessive consumption and tariff and cost manage-
software that is compatible with over 90% of measuring
ment. For more information, visit www.dexmatech.com
GAMO Case Study enginyeria eficiència energètica
Savings Measurements & Results Improvements in Thermal Process Management Process standby hours were reduced to meet production needs, which resulted in a schedule consumption reduction from 3:00 am to 8:00 pm.
Annual Savings:
3.500 € -10%
in thermal processing
Annual Savings:
8.210 €
Wastewater Treatment GAMO invested 2000€ to reduce water flow in the treatment system’s evaporator – the principal energy consumer – without compromising quality levels.
-25% in wastewater treatment
Passive Consumption. Power consumed was reduced from 10kW a 3kW by detecting and eliminating almost all non-essential consumption during passive hours (nights, holidays and weekends) and improving company-wide energy awareness and behaviors.
Annual Savings:
3.700 € -70%
in passive consumption
GAMO Case Study enginyeria eficiència energètica
Savings Measurements & Results LED Lighting Installation and Assembly Hall Sensors The GAMO assembly hall has a zone of non-stop use (24 hrs/ 241 days a year) which was previously lit by 12 x 300w (3.6 kW) projectors. 3ex4 replaced the system with 12 LED x 100W (1.2kW) projectors which resulted in an immediate 66% savings.
Annual Savings:
2.000 €
Light sensors were also installed to regulate the switching on and off of lights and set to take advantage of ambient lighting. The improvement reduced overall lighting time by 30%.
-76%
GAMO invested a total of €3700 in materials and installation, which was absorbed in 1.8 years by its over €2000 in annual savings.
in assembly hall lighting
Overall Results Comparing Base Year 2010 vs. 2011-2012, by production KPI Energy performance per unit manufactured fell by 28% within two years.
2010
kWh/u
[-15% diff.]
2011 [-28% diff.]
ROI
2012
24.300 € investment 2012 data
÷
54.600 € annual savings
= 5,3 months