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The Complex Manufacturing Challenge: Energy Installation with Zero Disruption
Food & Beverage Manufacturing
Live Environment
Heavy Engineering
Zero Downtime
The Mueller Copper Tube Heavy Manufacturing facility was facing prohibitively high and volatile electricity costs. The strategic solution was the installation of a new, on-site 2.5 MW gas-powered engine to generate their own power, managed by our client, Eon.
Case Study In Numbers
Engine weight
50 Tonnes
Safely installed over live production lines.
Annual savings
£1 Million+
Recurring electricity cost reduction for the client
Production downtime
0 Hours
Complete installation achieved without a single operational stoppage.
Energy capacity
2.5 MW
New gas-powered engine providing on-site energy independence.
Project duration
28 Weeks
Delivered on time and on budget.
Logistics precision
5 AM
Scheduled road closures for minimal public disruption.
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The Challenge: achieving energy independence while demonstrating impeccable Project Management
"The project wasn't just about reducing costs; it was about achieving energy independence while demonstrating impeccable project management. Every lift, every connection, and every cable route had to be meticulously planned to prevent costly downtime." - Legacy Manufacturing Solutions.
The Risk: Total Reliance on Costly Grid Power
Prior to the project, the facility was entirely dependent on the national grid for its power supply. This reliance exposed the business to fluctuating market prices and significant weekly electricity invoices. Any solution had to not only provide long-term energy savings but also be implemented without causing costly downtime that would negate the financial benefits of the investment. This was a critical risk mitigation exercise.
The Solution: Meticulous Planning and Expert Execution
Key highlights of our expert on-site management and execution included:
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Complex High-Voltage Work: We installed a new synchronising breaker in the client’s existing switch room, situated centrally in the production hall. High-voltage cabling was carefully routed through the roof trusses using a specially designed crane scaffold, enabling us to work safely above live machinery without interference or disruption.
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Live Gas Connection: We utilised a highly specialised "hot tap" technique to connect to the existing gas supply. This delicate operation was completed safely on the live main, ensuring no interruption to the site's ongoing gas supply—eliminating any associated risk.
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Precision Logistics & Site Management: The delivery of the 50-tonne engine container required careful road closures and was precisely scheduled for 5 am to minimise public disruption. The massive unit was then expertly reversed down a tight site road and hydraulically lifted from the transport onto its pre-built foundation.
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The Outcome: Over £1 Million in Annual Electricity Savings
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The programme was delivered on time and on budget, providing the client with a powerful, efficient, and resilient on-site energy source.
The direct result is a weekly electricity saving of approximately £20,000-£25,000, which translates to over £1 million per year. This successful installation has drastically reduced the facility's operational costs and carbon footprint, demonstrating how complex energy projects can be seamlessly integrated into live industrial environments with zero disruption.
Proven Results. Documented.
We don’t just claim to take the pain out of project delivery; we have the track record to prove it. Download our Industry Impact Pack to see how we’ve delivered for brands like Pepsico, Weetabix, and more. Button: Download All Case Studies
Built on a Foundation of Integrity.
We don’t just claim to be experts; we prove it. Our accreditations are an independent assurance of our commitment to quality management, environmental responsibility, and operational safety on every single site.
Contact Us Today to Discuss Your Project's Requirements and Start Your Energy Savings Strategy
Are you planning a complex energy or plant installation that requires zero disruption to your core business and demands expert project management? We deliver large-scale projects with financial foresight and technical precision.
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