December 2025
The Challenge: Inefficient Legacy Systems and Rising Costs
A leading manufacturing facility was facing a common industrial challenge: spiralling energy bills driven by an ageing, fragmented infrastructure. The site relied on multiple legacy Building Management Systems (BMS), including unsupported Trend IQ2 controllers, which operated in isolation.
For the facilities management team, this created a significant operational burden. With no remote visibility, staff had to physically walk to various BMS panels across the factory floor to check configurations or troubleshoot issues. This lack of data meant that heating was frequently left in ‘manual on’ mode rather than ‘auto’, and there was no way to track temperatures, setpoints, or system faults. Without centralised insight, identifying energy waste was impossible.
The Solution: ecoDriver Energy Management and BEMS Integration
ecoDriver was brought in to overhaul the site’s energy infrastructure and implement a robust monitoring and control strategy. The project focused on transitioning from reactive maintenance to proactive energy management.
Key interventions included:
- Start measuring granular energy using ecoDriver, giving the empirical evidence of where and when there was consumption, and how much.
- BMS Modernisation: Replaced legacy Trend IQ2 hardware with a modern, networked, open-source solution.
- Centralised Visibility: Implemented a BEMS platform accessible via the local network. Facilities managers can now view live temperatures and system statuses on interactive site maps from any desktop or mobile device.
- Precision Control: Replaced faulty temperature sensors and integrated wireless outside air temperature interlocks to ensure heating only operates when environmental conditions require it.
- AI-Powered Insights: By leveraging ecoDriver’s cloud-based software, the manufacturer can now interrogate data to spot anomalies. This is further enhanced by EDDIE, our AI sustainability bot, which provides ongoing guidance on maintaining efficiency.
The Results: Data-Driven Savings
To accurately measure the success of the project, a linear regression analysis was performed, comparing gas consumption against Heating Degree Days (HDD). This ensured that the savings were calculated based on actual performance, accounting for the fact that the post-installation period was significantly colder than the previous year.
Financial & Operational Impact:
| Metric | Before ecoDriver | With ecoDriver |
| Annual Gas Spend | £135,000 | £91,800 |
| Annual Savings | – | £43,200 |
| Percentage Saving | – | 32% |
| Return on Investment | – | 6 Months |
Despite the colder weather in the second year, the facility consumed 345.9 MWh less than expected. The project achieved a full return on investment in just six months, proving that smart energy management is one of the most cost-effective ways for manufacturers to reduce overheads.
Summary and Future Outlook
By eliminating energy waste and centralising control, this manufacturing site has dramatically reduced its carbon footprint and operating costs. However, the journey doesn’t end with installation.
The facility continues to use ecoDriver for systematic analysis to ensure these savings are maintained long-term. Future phases of the project are already being discussed, including the installation of door interlocks to further prevent heat loss in high-traffic loading areas.
For manufacturers with large, complex buildings and unoptimised controls, this case study highlights the significant financial rewards of moving to a modern, AI-enhanced energy management platform.
Find out how ecoDriver could achieve similar at your site, here.
