Polystar Plastics

Client Overview

Polystar Plastics is a UK-based plastics manufacturer operating an industrial production facility with a range of energy-intensive processes. As part of their commitment to improving operational efficiency and meeting regulatory requirements, Polystar Plastics commissioned Inteb to complete an Energy Savings Opportunity Scheme (ESOS) assessment.

Given the nature of plastics manufacturing, the site’s energy profile is driven by high-demand equipment such as extrusion presses, electric motors, water chillers, and compressed air systems, alongside general site services including heating, ventilation, cooling, lighting and hot water.

Polystar Plastics sought expert support to understand their energy consumption patterns, quantify their associated carbon footprint, and identify practical opportunities to reduce both energy use and operational costs while maintaining production performance.

Client Objectives

Polystar Plastics aimed to strengthen their energy management and sustainability performance through the following objectives:

Comprehensive ESOS Assessment:

• Conduct a detailed ESOS report covering energy consumption across all major systems including electricity, transport fuels and site utilities.
• Analyse energy use from grid electricity and diesel consumption for onsite forklift trucks.

Energy Performance Analysis:

• Review half-hourly electricity data to identify trends, patterns and anomalies within the site’s energy consumption.
• Assess energy use across key systems such as extrusion presses, compressors, chillers and electric motors.

Energy and Carbon Footprint Reporting:

• Quantify the organisation’s energy use and associated carbon emissions.
• Develop a suitable energy intensity metric reflecting the operational nature of the manufacturing process.

Identification of Energy Saving Opportunities:

• Identify practical measures to reduce energy consumption and emissions.
• Provide estimated annual cost savings, carbon reductions and energy savings, alongside implementation costs and expected payback periods.

Our Approach and Results

Inteb worked closely with Polystar Plastics to gain a detailed understanding of their operations and energy usage, ensuring the ESOS assessment reflected the challenges of a working manufacturing site.

1. On-Site Assessment and Operational Insights

To ensure a comprehensive understanding of the site, our team conducted a site visit to observe production processes and identify high-energy equipment in operation. This allowed us to:

• Document and photograph key energy-intensive equipment including extrusion presses, compressors and chillers.
• Understand how energy is used across production processes and support systems.
• Identify areas where energy monitoring and operational improvements could be implemented.

2. Energy Data Analysis

A detailed analysis of half-hourly electricity consumption data was carried out to identify:

• Operational trends and load patterns.
• Energy use peaks linked to production processes.
• Potential anomalies and opportunities for improved energy management.

Due to the nature of plastics manufacturing, traditional intensity metrics such as floor area or employee numbers were not appropriate. Instead, we explored alternative approaches to develop a more meaningful energy intensity indicator aligned with production activity.

3. Identification of Energy Saving Opportunities

The ESOS assessment identified seven energy saving opportunities across the site. Each measure included estimated:

• Annual energy savings (kWh)
• Carbon reductions (tCO₂e)
• Cost savings (£)
• Implementation costs
• Payback period

One key recommendation involved improving energy monitoring and targeting through the installation of sub-metering systems. By providing better visibility of energy use and encouraging behavioural changes among site staff, Polystar Plastics could potentially achieve savings of approximately:

• £93,000 per year
• 107 tCO₂e per year

Across all identified opportunities, the average payback period was approximately 4.4 years, demonstrating strong financial and environmental benefits from implementing the recommended measures.

Conclusion

Through our ESOS assessment, Polystar Plastics gained a clearer understanding of their energy consumption, operational efficiency and carbon footprint. By combining on-site observations, detailed data analysis and practical energy reduction recommendations, we were able to identify a number of opportunities to reduce costs and emissions across the site. This project highlights how industrial

manufacturing facilities can benefit from targeted energy analysis and improved monitoring, enabling organisations to reduce energy waste and improve operational efficiency.

If Polystar Plastics’ success inspires you to explore similar initiatives within your organisation, we invite you to get in touch with us. Follow us on LinkedIn or visit our website to learn more about how we support businesses in improving energy performance and reducing their carbon footprint.