Improving the use of Buildings & Resource Efficiency Improvements, UK

AP Burt & Sons Ltd are a major printer of retail branded paper and polythene bags, producing some 6 million bags per day.

AP Burt & Sons has occupied the same site in Portishead for over 70 years. During this time the factory has seen many changes and alterations; including being used as a vehicle assembly plant during the 2nd World War.

James Nichols, Financial Director, commissioned Abricon to perform a full review of the suitability of the many production and warehousing areas, emphasising the need for fully cost justified proposals for any changes that were recommended.

The first task was to independently verify the recommendations of their compressed air contractors for a replacement compressor. Using demand profile data from the existing compressor, and taking into account improved efficiencies of modern compressors as well as improving the pipe runs to machinery, we determined that the recommended replacement was over-sized for requirement. However, taking into account projected company growth figures, the uplift in capacity was acceptable.

Abricon then reviewed water usage, focusing in particular on the two sets of urinals in the older parts of the factory. Water is an expensive commodity as companies are charged for supply, and again as a return to sewer charge. Any reduction in water use therefore impacts on two bills. Flush timers had been fitted to the urinals, but these were operating 24 hours a day, 365 days per year. Modern flush controls operate on water pressure and only flush when sink taps are operated. The fitting of this device had a payback period of a single weekend, and led to an annual saving of over £5,000.

Finally, Abricon investigated floor space need against actual usage. One of the warehouses was used to store a small quantity of printing inks requiring a certain minimum temperature. Consequently, the entire warehouse (10,000 sq, m.) was heated. We recommended the use of a smaller, better insulated warehouse, enabling the heating to be switched off in the larger warehouse.

This measure both greatly reduced the amount of CO2 generated and saved money; a win-win scenario for both AP Burt and the environment!