40% savings achieved for JCB with new control system
JCB
Manufacturing
Building Energy Management
Background
JCB appointed YLEM Energy to upgrade their outdated control system to our cutting-edge technology which is designed and built by our in-house engineers.
Challenge
JCB’s existing Seachange controls had become outdated and unfit for purpose, updating these would allow the business to improve energy efficiency, reduce costs and help them on their journey to net-zero. The existing control system could only be accessed through a local PC which meant unless an employee had access to this the controls couldn’t be changed remotely.
Solution
YLEM Energy worked closely with JCB to develop a tailored solution to upgrade their obsolete control system.
Our expert team designed and built the new system which was installed in just under a week and despite taking place during the peak heating season it was carried out with minimal disruption and downtime, this was aided by the fact that we could utilise the existing network and sensor cabling.
The site has a centralised heating and ventilation control panel, adjacent to which we mounted an additional enclosure with the new controls in ensuring that we left adequate room for future expansion. Additional controls were added for the customer to switch compressors and production pumps on and off via a time base accessible on our app, this meant that there was no risk of forgetting to turn these off and needlessly running out of hours.
The heating of the production areas consists of 65 gas-fired radiant tube-style heaters split over 11 zones. Ventilation is provided via extract fans and roof vents operated for cooling and extraction of welding fumes.
Result
Updating the existing control system allowed JCB to achieve 40% savings on their energy bills. The old analogue phoneline required for remote support and reporting features for Seachange is no longer required resulting in an additional cost saving.
As the new controllers can be remotely updated and engineered, universal inputs and outputs can be programmed for the customer from the YLEM Energy Remote Support Centre. Additional meter points have been added allowing the customer to wire themselves without the need for an YLEM Energy engineer to attend site.
Holidays and planned shutdowns can now be scheduled into the system years in advance if required and exceptions to the time schedules can be easily added.
JCB was most impressed with the animated graphics pages, and the ease of use. Changes to the graphics are easily carried out and once complete, can be seen by all users without relying on updated local PC files.
Find out how much you could save
Phone: +44 (0)161 660 2222
Email: solutions@ylemenergy.co.uk
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Mike Thompson — Project EngineerNow that the system is fully upgraded, JCB can look forward to using a modern system capable of maintaining and building upon the savings achieved since the first Seachange controllers were installed. They also have a system that can be accessed on any smartphone or tablet to show real-time data.
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