Case Study
Manufacturing
GAMO
GAMO reduced its energy costs by 28%, securing its competitiveness in the sector with the help of 3ex4 and the DEXMA Platform.
Client
GAMO Outdoor has been manufacturing rifles, guns and bullets for 50 years.
It is the European leader in the manufacture of air rifles and a world leader in the manufacture of high quality ammunition and carbines. Customers in over 80 countries count on its innovative technology, which results from continuous investment in new production processes that combine craftsmanship and technology.
Challenge
GAMO’s project objective was to reduce energy expenditure by implementing an organisation-wide energy management system,
establishing energy policies, circulating communication campaigns and training employees at all levels.
The initial goal was set at a 10% reduction. Given the company’s increased rate of production over the two previous years, it needed to set cost per unit manufactured as a key indicator, and be able to use its energy management tool to analyse the relationship between its consumption and this variable.
Case Study
Manufacturing
2,500,000 kWh
Annual energy consumption
€350,000
Annual consumption
28%
Consolidated savingsProject implemented by:
ROBERT MARTÍNEZ
Consulting Partner, 3ex4
-
It’s the best option on the
market. The DEXMA Platform is
powerful, rapidly evolving and
meets all our requirements.
Solution
In late 2010, the company performed an energy audit, using the DEXMA Platform to monitor the electrical consumption of its four industrial buildings, as well as monitoring its main sub-meter consumption at the beginning of 2011.
3ex4 and GAMO implemented numerous improvements between 2011 and 2013.
JOSEP CENTELLES
Industrial Director, GAMO Outdoor
We managed to implement a company-wide energy
efficiency protocol that
enabled us to reduce energy costs by 20% annually,
increasing our market
competitiveness while involving the entire organization in our
energy efficiency efforts.
Taking 2010 consumption levels as a reference, the improvements implemented reduced GAMO’s cost per unit manufactured by 15% in 2011, and lowered the cost per unit by 28% in 2012.
A total of 15 energy management improvements and investments were applied between 2011 and 2012, which together demonstrated an ROI of under a year, revealing a tremendous opportunity for companies in the industrial sector to realise energy savings in a short period of time.
Total savings during the first two years exceeded €85,000. GAMO and 3ex4 together dynamically reduced energy consumption, increased the company’s competitiveness, and instilled an energy-savings culture across the organisation.
DEXMA creates energy savings and management software solutions for a range of sectors including corporate, public administration, the service sector, and the industrial and residential sectors. Its software is distributed through a network of partners that include utility companies, maintenance firms, ESCOs, integration consultants, installation companies, energy distributors and telecoms.
The DEXMA Platform is a 100% web-based energy management software that is compatible with over 90% of measuring equipment and SCADA/ BMS systems.
The software enables invoice management, real-time monitoring of energy consumption, remote meter reading, and visibility of consumption of all energy subsystems.
DEXMA offers basic functionalities, such as profile-specific dashboards, reporting and alerts, as well as more advanced features, such as benchmarking, detection of excessive consumption and tariff and cost management. For more information, visit www.dexma.com.
The Results of the Project
-10%
In Thermal Processing€3,500
Annual Savings
Improvements in Thermal Process Management
Process stand by hours were reduced to meet production needs, which resulted in a scheduled consumption reduction from 3:00 am to 8:00 pm.
Wastewater Treatment
GAMO invested €2,000 to reduce water flow in the treatment system’s evaporator – the principal energy consumer – without compromising quality levels.
-25%
in Wastewater Treatment€8,210
Annual Savings
Saving measurements
and results
Passive Consumption
Power consumption was reduced from 10kW to 3kW by detecting and eliminating almost all non-essential consumption during passive hours (nights, holidays and weekends) and improving company-wide energy awareness and behaviour.
in Passive Consumption
-70%
€3,700
Annual Savings
LED Lighting Installation and Assembly Hall Sensors
The GAMO assembly hall has a zone of non-stop use (24 hrs/ 241 days a year) which was previously lit by 12 x 300W (3.6 kW) projectors. 3ex4 replaced the system with 12 LED x 100W (1.2kW) projectors which resulted in an immediate 66%
saving.
Light sensors were also installed to regulate the switching on and off of lights and set to take advantage of ambient lighting. The improvement reduced overall lighting time by 30%.
GAMO invested a total of €3,700 in materials and installation, which was paid backin 1.8 years by its over €2,000 in annual savings.
The lighting savings continued in future years achieving further improvements.
-76%
in Assembly Hall Lighting€2,000
Annual Savings
Overall Results by Production KPI
Energy performance per unit manufactured fell by 28% within two years.
2010
[-15%
diff.] [-28%
diff.]
2011 2012
kWh/u
DEXMA By Spacewell Caso de Éxito - Industria GAMO 6
meses
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ROI €24,300 €54,600
investment
