Airedale Springs
Project Overview
Carbon Negative A+ EPC Rating
Founded in 1945, Airedale Springs www.airedalesprings.co.uk is located in a purpose-built factory in West Yorkshire. It is an industry-leading, bespoke manufacturer of mechanical springs and 3D wire forms supplied to a diverse range of national and international customers.
An award-winning AlphaGen Energy Project that has achieved a Carbon Negative A+ EPC Rating and won the Sustainability Award at the ‘Bradford Means Business Awards 2024.
The project is being considered for further regional and national awards to be announced by year end.
The Problem
No control over energy costs
In mid 2022, Airedale Spring’s utility provider gave notice of a 285% projected increase in energy bills due for late 2023. Such a hike would have a bottom-line impact on the business. Airedale Springs also faced mounting pressure from their supply chain and client base to demonstrate ESG and CSR commitment. This demand matched the CEO’s passion to be seen as a bellwether company in its sector for driving a path to carbon reduction and offgridding – no easy task given the nature of the business and power needs.
Airedale Springs approached AlphaGen Energy in early 2023 to undertake a full review of operations and design a renewable energy solution to substantially reduce electricity costs, future-proof the business and produce measurable and quantifiable data to prove the pathway to carbon neutrality.
The solution
AlphaGen Energy’s proven 3-phase approach
Data
- AlphaGen led interviews with the Client’s leadership team to understand day to day work patterns and to align with forward business objectives.
- A full review of current operations and hours of operation plus new work practices.
- A review of the premises and power provision on site.
- Installation of AlphaGen’s prefix proprietary metering to provide a granular understanding of load and power demand down to an individual meter.
- Consideration of 3-year annual electrical bills and half-hourly data.
- A review of a dated PV array in situ via physical and thermal drone surveys.
Strategy
- A full data-backed solar and battery storage Master Plan to “attack” grid dependency and consumption, reduce OPEX and meet CSR/ESG objectives.
- Prime focus on measurable and quantifiable carbon reduction and to future-proof onsite energy requirements.
- Optimisation and upgrade plans to repair and replace low-wattage PV panels and firstgeneration inverters.
- Design and costings to install next generation SunSynk Inverters, battery energy storage solutions and latest high efficiency PV panels.
- A tailored “on site” AlphaGen Energy Management System operational from Day One.
- Full engineering, procurement and construction budgeting with installation phasing for Client review and approval.
- Engagement with the District Network Operator and Planning Department on behalf of the Client to review the scheme and secure permits.
Installation
- A comprehensive upgrade of the in-situ PV array to include the removal and recycling of existing panels.
- Installation of 438 rooftop solar panels paired with X3 SunSynk 50Kw inverters and X3 61 kWh battery racks housed in a standalone secure unit.
- Installation of AlphaGen’s proprietary Energy Management System providing real-time monitoring to include widescreens in the main production areas for staff and visitor viewing.
- Full performance commissioning and testing for planning compliance, manufacturer warranties, DNO approvals and Health and Safety purposes prior to certification and handover
- AlphaGen’s Operation & Maintenance and bi-annual health checks.
- SunSynk’s 24/7 real-time live APP and UK-based non-bot, 24/7 technical support.
The PV Bess and EMS went live in Sept 2023
The results
- Energy costs significantly reduced driving operational efficiency and margin improvement.
- 80% of Airedale Spring’s annual energy need is generated from the AlphaGen energy solution.
- The business is grid-free in the key energy production period April-September.
- The EPC assessment returned an EPC A+ Carbon Negative Certification described as “outstanding” and a “unique” achievement.
- Airedale Springs is winning awards for Business Sustainability.
- Airedale Springs is exporting surplus energy back to the grid for revenue.
- Inspections by Government MP, national retailers and multi-sector multinationals resulted in requests for scaling into their portfolios.
Downloadable Whitepaper
Click below to download the Airedale Springs full case study
