OPEXA
Case study · 2025

26% energy intensity reduction at a heavy industrial plant.

Energy intensity was 19% above peer benchmark. We rebuilt the energy management system, deployed metering, and reset operating standards.

26% energy intensity reduction at a heavy industrial plant.

26%

Energy intensity reduction

$14M

Annualized savings

ISO 50001

Certification achieved

12pts

ESG score improvement

Challenge

The starting condition.

Energy intensity 19% above peer benchmark, with limited visibility into where energy was lost. Sustainability commitments required a 25% intensity reduction within 18 months — without capex.


Approach

What we did,
in order.

  1. 01

    Energy diagnostic mapping: 47 metering points installed.

  2. 02

    Operating standards reset for compressed air, steam, and electrical loads.

  3. 03

    Operator energy-awareness training for 220 personnel.

  4. 04

    Energy KPIs added to daily plant review.

  5. 05

    Energy management system built to ISO 50001 standard.


Results

What was sustained,
at month twelve.

  • 26% energy intensity reduction (against 25% commitment)
  • $14M annualized savings
  • ISO 50001 certification achieved
  • 12-point ESG score improvement (sustainability index)
  • Energy management function permanently established
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