Case study · Manufacturing
Kellogg's, Trafford Park
A household-name manufacturer achieved 7–8% energy savings from a single voltage-tracking optimiser. £40,227 per year and 243 tonnes of CO₂ avoided, on a site with loading swings that ruled out standard fixed VO.
The site
What we were dealing with.
Kellogg's have been working for years to continually improve their environmental performance, specifically reducing energy use, greenhouse gas emissions, water use, and waste sent to landfill.
As part of this programme, the Trafford Park facility was surveyed to identify actions to reduce energy consumption. Voltage optimisation was identified as beneficial in reducing the Manchester facility's energy consumption and offering considerable cost savings.
During the datalogging process it became clear that the site suffered from large loading swings, making it unsuitable for standard forms of fixed voltage optimisation. Volta was the only company that could supply a single optimiser solution capable of handling the site's specific conditions.
| Sector | Manufacturing |
| Site size | Major manufacturing facility |
| Operating pattern | Continuous food manufacturing, large loading swings |
| Baseline voltage | — V |
| Post-install voltage | — V |
| Annual kWh saving | 463,176 kWh |
The install
What we did.
An EMP1800s Staged Voltage Tracking Power Optimiser was specified, with a custom cable termination compartment designed for the site's electrical configuration.
The voltage-tracking design was essential: the site's large and variable load profile meant a fixed-output optimiser would have delivered inconsistent results. The tracking unit adjusts continuously to maintain optimal voltage reduction regardless of load conditions.
The result
What we measured.
Annual energy reduction of 463,176 kWh, delivering savings of £40,227 per year, a 7–8 % average reduction in site electricity consumption.
Against a project cost of £71,062, the payback period is 21.2 months. CO₂ emissions reduced by 243 tonnes per annum.
The project demonstrates VO working at scale on a site with challenging loading conditions. The custom tracking solution delivered consistent savings where a standard fixed-output unit would not have been viable.
Measurement & verification method
Pre-install datalogging to establish baseline consumption, followed by post-install datalogging to measure actual savings. Kellogg's on-site engineering team were involved throughout the survey and measurement process.
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