KTS Wire

The Challenge

KTS Wire (KTS) is a specialist wire manufacturer and supplier based in Leeds, and is part of the Suzuki Garphyttan Group. The wire is used in a wide range of sectors including automotive, textile, bedding, agriculture, fencing, household goods, construction, and safety mechanisms.

As part of its strategy of continuous improvement, KTS recognised that an expert energy consultant could help it identify savings and ensure its energy costs remained within budget, enhancing its reputation for innovation and technical expertise.

The company appointed us to:

• Reduce energy costs.
• Eliminate unnecessary waste and charges.
• Improve long-term visibility of energy costs.

The Solution

First, we undertook a thorough discovery exercise and energy audit of KTS’s production processes, evaluating their suitability for available subsidies. We also analysed the company’s consumption and billing data to identify wastage and opportunities to increase its energy efficiency.

We proposed that KTS could benefit from a scheme that provides rebates on government levies. Our ongoing management of KTS’s submissions for this scheme has so far resulted in annual savings of £172,000.

We also identified that poor power factor was costing KTS £8,500 a year in avoidable costs relating to excess capacity charges, CO2, emissions, kWh losses and reactive charges. Installing power factor correction equipment rectified the issue and paid for itself in just 2.6 years.

Thirdly, we recommended that KTS adopted a risk-managed approach to procurement and utilised state-of-the-art technology to gain full visibility over its energy use and costs.

Pulse, our bespoke energy-management software, provides a robust and accurate energy budget for a rolling three-year period. Future costs are accurately forecast, accounting for daily price movements. Ceilings are set to limit exposure to rising prices, and markets are monitored daily to ensure optimal timing of purchase decisions. 

The Benefits

In total, our recommended measures have resulted in annual savings of over £200,000 for KTS, including the elimination of £8,500 a year in waste costs.

For a cost-transparent fixed fee, KTS now not only enjoys substantial savings and budget certainty but also peace of mind that they’re working with a trusted partner focused on delivering tangible results.