Manufacturing, engineering and warehousing
Cut energy costs across your plant.
Keep the line running.
Motors, compressors, chillers and high bay lighting run every shift. We cut the power they waste with voltage optimisation, power factor correction and live monitoring, then verify every kWh against a baseline you sign before we start.
BICS will lower your unit rate. Your plant will still waste power.
From April 2027 eligible manufacturers get policy costs taken off their electricity bills. That helps, but it does nothing about the motors running on over voltage or the compressor left on all weekend.
Cut the rate and cut the kWh, and the two savings stack.
Off electricity bills for eligible manufacturers
The British Industrial Competitiveness Scheme removes Renewables Obligation, Feed in Tariff and Capacity Market charges for around 10,000 electricity intensive firms.
Check if you qualifyLarge businesses need to show progress
Phase 4 asks for an energy audit and a plan you can report against. Verified savings from Pulse give you real numbers to put in it.
Talk to us about ESOSYour customers want your carbon data
More buyers now ask suppliers for energy and emissions figures. Metered kWh and carbon by site makes that request a quick one to answer.
Ways to cut cost and carbonMost of the waste on a factory floor sits in five places.
Every site is different, so your own figures come from your half hourly data. These are the loads we look at first.
Motors, pumps and fans
Conveyors, extraction, pumps and process fans. Most run at fixed speed and on higher voltage than they need, so they burn power as heat.
We fit: Voltage Optimisation, Pulse ControlCompressed air
A single 3mm leak can cost around £1,000 a year. Compressors left running through breaks and weekends cost far more than that.
We fit: Pulse monitoring and out of hours alertsPoor power factor
Half hourly metered sites pay reactive power charges in any half hour where power factor drops below 0.95. It also eats into the capacity on your supply.
We fit: Power Factor CorrectionHarmonics
Variable speed drives and welders push distortion back into your network. Cables and transformers run hot, breakers trip and motors wear out sooner.
We fit: Active Harmonic FiltersRefrigeration, lighting and HVAC
Walk in fridges and freezers, high bay lighting and heating in big sheds. Loads that run whether the line is busy or not.
We fit: KBR Refrigeration, Pulse ControlSources: Carbon Trust, Business Climate Hub, UK DNO charging statements. Figures are sector averages, not a quote.
Energy saving that fits the way your site runs.
From single factories to national logistics networks. We work around your shift pattern and planned maintenance, so output never takes the hit.
Manufacturing and food production
Processing, packaging and process cooling. We cut the waste in motors, compressed air and refrigeration without touching output.
Industrial sites and factories
Heavy machinery, high bay lighting and ventilation. Bring down peak demand and stop paying reactive power charges.
Engineering and machining
CNC, welding and automated cells. Clean up power quality so drives run cooler and nuisance trips stop.
Warehousing and logistics
Lighting, HVAC, conveyors and cold storage across big floor areas. Savings you can see site by site.
Printing and publishing
Presses, finishing lines and climate control for paper and ink. Lower running costs on long print runs.
Farming and agriculture
Grain drying, irrigation pumps, milking parlours and cold stores. Cut electricity costs across the farm.
Start at the incomer. Then go machine by machine.
Voltage optimisation and power factor correction treat the whole site in one go. Controls and monitoring then find the rest. Every kWh verified in Pulse.
Voltage Optimisation
UK mains often arrives at 240 volts or more. Most motors, drives and lighting are built to run lower than that, and you pay for every extra volt as wasted heat. Voltage optimisation brings the whole site down to a level your kit runs well at. Motors run cooler and last longer.
Power Factor Correction
Capacitor banks sized to your load keep power factor above 0.95. No more reactive power charges on your bill and more usable capacity on the supply you already pay for.
Learn more Power qualityActive Harmonic Filters
Detect and cancel harmonic currents from drives, welders and UPS in real time. Keeps you inside G5/5 limits and protects cables, transformers and motors.
Learn more ControlPulse Control
Wireless energy management for every asset on site. Schedule compressors, HVAC, lighting and pumps to your shifts so nothing runs when nobody is there.
How Pulse Control works Monitor and verifyPulse
Live energy monitoring by site, building or line. IPMVP verified savings reports and the data you need for ESOS, SECR and customer carbon requests.
How Pulse monitoring works Walk in fridges and freezersKBR Refrigeration EnergySaver
Fitted to the compressor on your walk in cold rooms. It cuts run time without letting temperatures drift, saving at least 7 kWh a day on a walk in fridge and 14 kWh a day on a walk in freezer.
How KBR Refrigeration works
Solar PV and BESS
Big roofs and daytime shifts suit solar. Add battery storage to shift load away from peak rates. Sized to your load and tariff, not the biggest system that fits.
Learn moreEvery line and every shift on one screen.
This is Pulse. It shows what each site, building or line used, what it saved and when something starts to drift. Your site manager can read it without calling an engineer.
+11% vs last week
+8% vs last week
Today
Proven on UK factory floors, verified to IPMVP.
Saved for UK manufacturers through targeted voltage optimisation and controls. Every kWh measured against a signed baseline.
Most industrial clients see their investment paid back in around 14 months. We put the payback in writing before you commit.
Tell us what you make and how you run, and we will send the case study closest to your site, including the baseline and the verified result.
Request case studiesSurvey. Fit. Prove.
A free energy audit first. Then we fit what makes sense for your site and measure every kWh, so the saving shows up in your accounts.
Survey
Send half hourly data or three months of bills. Our analysts run a free energy audit and come back with your number by end of the working day.
Fit
Our own engineers install at the incomer and on the assets that matter. We plan the work around your production schedule and maintenance windows.
Prove
Every kWh is checked against the baseline you signed, to IPMVP standard, and reported to you in Pulse.
See what your site could save.
A rough guide only. Your real figure comes from your own data and we send it back the same working day, free.
Your site type and annual spend.
A typical yearly saving for this kind of site from voltage optimisation, power factor correction and Pulse Control. Reactive power charges you stop paying come on top.
Want a real number instead?
Send your half hourly data or three months of bills. Our analysts come back with a guaranteed savings proposal by end of the working day. Or grab 30 minutes with Alex first.
Energy saving for manufacturers, answered.
How much can a manufacturing site save on energy?
Most industrial sites we work with cut electricity use by up to 15 percent. The biggest share usually comes from voltage optimisation on motor heavy sites, then from switching off plant that runs when nobody needs it. Power factor correction removes reactive power charges on top of that. Your own figure depends on your supply voltage, your equipment and your shift pattern, so we work it out from your half hourly data first.
Will voltage optimisation affect our machinery or production?
No. Your equipment still runs inside its rated voltage range, so output is the same. Motors actually run cooler because they are not being overfed, which helps them last longer. We check your equipment list and supply readings before we recommend a setting.
What is power factor correction and do we need it?
Inductive loads like motors, compressors and welders draw reactive power that does no useful work. If you have a half hourly meter and your power factor drops below 0.95, your network operator charges you for it. Power factor correction fits capacitor banks at the supply to fix that. If reactive power charges show on your bill, or you are running close to your agreed capacity, it is worth looking at.
Our drives and welders cause harmonics. Can you deal with that?
Yes. Active harmonic filters measure distortion on your network and cancel it in real time. That keeps you inside the G5/5 limits your network operator expects and stops cables, transformers and motors running hot. We measure your harmonics first so the filter is sized to your site.
We may qualify for BICS. Is it still worth cutting consumption?
Yes. BICS takes certain policy costs off the unit price from April 2027 for eligible manufacturers. It does not change how many kWh you use. Cutting consumption lowers the rest of your bill, including wholesale and network costs, and it counts towards your carbon targets. Use our BICS eligibility checker to see if you qualify, or read the free BICS readiness guide.
Can this help with ESOS and carbon reporting?
Yes. Pulse records metered kWh by site and reports savings to IPMVP standard. That gives you verified figures for your ESOS Phase 4 action plan, your SECR report and carbon data requests from customers.
How long does installation take and will we have downtime?
Our own engineers do the work, with no subcontractors. Connecting at the incomer needs a short planned isolation, so we book it into a weekend, a shift change or a maintenance window you already have. Multi site groups get a rollout plan site by site.
What does it cost and how quickly does it pay back?
Price depends on your supply size and how much of the site you want to control. Most industrial clients see a return in around 14 months, and we guarantee the payback in writing before you commit. Send us one site and we will come back with a costed proposal by end of the working day. There are no consultant fees.
Still weighing it up? Send us one site and get a free savings proposal by end of the working day.
