Overview
Bott Ltd, a leading UK manufacturer of workplace storage equipment and van racking systems, has been committed to sustainable practices for over 40 years. As part of its ongoing efforts to reduce its carbon footprint, the company sought to optimise energy consumption in its manufacturing facility in North Cornwall.
A key area of focus was the powder coating line, where a 37kW fan continuously recovered unused powder from the spray booth atmosphere. The fan motor was started using a soft starter and operated at full speed throughout production, resulting in high energy consumption and inefficiencies. Recognising the potential for improvement, Bott Ltd approached APDS, specialists in energy-saving solutions.
Solution by APDS
APDS worked closely with bott’s site engineering team to assess the fan application using a non-intrusive data logger. A single site visit provided APDS with the insights needed to recommend a cost-effective and energy-efficient solution, including:
- Analysis of the fan’s existing energy usage
- Identification of an optimised replacement solution with projected energy savings
- ROI calculations to support a data-driven investment decision
Implementation
APDS installed an IP55 ABB ACH580 Variable Speed Drive (VSD) to replace the soft-start controller. The system was optimised through:
- Speed Adjustment: APDS and bott’s engineers identified a minimum speed of 45Hz (10% reduction), verified via an anemometer.
- Additional Control Features:
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- A slow fan speed mode during process backups, further reducing energy consumption.
- A 100% speed mode for line cleans and powder colour changes.
- System Integration: New control relays were added to interface with existing line controls.
Results & Impact
Over a one-week period, APDS recorded the following energy savings, showing a payback period of less than 17 weeks.
| Metric | Pre-Installation | Post-Installation | Savings |
|---|---|---|---|
| Energy Consumed (kWh) | 1366.87 kWh | 428.16 kWh | 65% Reduction |
| Return on Investment (ROI) | < 17 weeks |
Conclusion
By leveraging innovative motor control technology and expert engineering, APDS enabled Bott Ltd to significantly cut energy costs while maintaining production efficiency. This project highlights how modern variable speed drive technology can deliver immediate and measurable sustainability benefits in manufacturing.
Are you ready to start your energy saving journey? Book a free energy audit with APDS today by emailing sales@apds.co.uk.
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