Aster cuts energy use across five production sites
Aster improved energy efficiency across five production facilities by identifying high-consumption processes use without slowing production.
Operational efficiency
Aster wanted to reduce energy consumption across its growing manufacturing network without disrupting production. With five facilities operating different equipment and processes, the company needed a consistent approach to identify inefficiencies and create measurable improvements across every site.
As production volumes increased, energy became a larger part of the company's operational costs. Aster recognized that improving efficiency could create both environmental and commercial benefits, but it needed better visibility into how energy was being used across its facilities before making meaningful changes.
The challenge
Energy usage varied significantly between facilities, making it difficult to identify where the biggest opportunities existed. Data was collected differently at each location, and teams lacked a unified view of consumption patterns. Aster needed a clearer system for comparing performance and prioritizing improvements.
The challenge was not simply reducing energy use, but doing so without affecting production schedules, product quality, or operational reliability. Each facility had its own equipment and workflows, so a single solution would not work everywhere.
The approach
We helped Aster bring energy data from all five facilities into a single operational framework. By analyzing consumption patterns, equipment performance, and production schedules, we identified areas of unnecessary energy use and created site-specific improvement plans. The process also established consistent reporting standards across the network.
The team then prioritized improvements based on potential impact and ease of implementation. Rather than making large disruptive changes, Aster focused on practical adjustments that could be introduced alongside existing operations.
The results
Aster reduced energy consumption across its five production sites while maintaining existing production levels. The new reporting framework gave teams greater visibility into operational performance and helped identify further opportunities for efficiency improvements.
Beyond the immediate reduction in energy use, the project created a repeatable system for managing operational efficiency across the business. Teams now have clearer data, stronger benchmarks, and a shared understanding of where future improvements can deliver the greatest value.
We now understand exactly where our energy is going and where we can improve. The visibility has changed how our teams approach efficiency across every site.
Daniel Mercer
Operations Director, Aster Manufacturing
