Improving operational resilience for an energy-intensive manufacturer
A UK manufacturer operating three production facilities had experienced sustained increases in electricity expenditure following prolonged volatility in wholesale energy markets. Although production volumes remained stable, energy costs had increased by around 38% between 2021 and 2024, placing additional pressure on operating margins. Similar cost pressures have affected manufacturers across Europe since the energy crisis, particularly businesses with energy-intensive production processes.
Romney Collins was engaged to undertake a broader operational review, considering the wider operational consequences of sustained energy-price volatility. The objective was to identify practical opportunities for reducing operational risk while supporting more efficient usage of existing resources.
Romney Collins assessed production scheduling, critical equipment dependencies, procurement arrangements and contingency planning to understand how operating practices influenced both energy consumption and resilience during periods of supply disruption or elevated electricity prices. The review also considered where greater operational flexibility could reduce exposure to peak-price periods without affecting production commitments.
The engagement identified opportunities to reduce annual electricity consumption by approximately 9%, consistent with savings commonly achieved through structured industrial energy management programmes. Our recommendations strengthened the organisation's preparedness for future disruption whilst reducing exposure to periods of exceptional wholesale electricity pricing.
