F.01
Continuous demand from compressed-air system
Largest single energy load on site. Control regime, leaks and pressure setpoints all in play.
KAB Seating — a 228,517 sq ft manufacturing facility in Northampton — came to KEES with two weeks until our site visit and an ESOS deadline closing fast. Here's how we used half-hour electrical data, a maintenance-week visit and a tight focus on practical findings to get them compliant — and identified 25% of total energy spend in available savings along the way.
Cost saving identified during ESOS audit, against KAB's full annual energy bill.
Annual energy reduction available from the recommended Action Plan measures.
Carbon equivalent of the energy saving, calculated using the UK grid factor.
Tight deadline, complex site, and an ESOS submission that needed to actually mean something.
KAB Seating manufactures specialist seating from a 228,517 sq ft facility in Northampton with continuous demand from a compressed-air system and an attached paint facility — two of the most energy-hungry processes in industrial manufacturing.
They came to KEES already late in the cycle. Time was not on their side and they were not in a position to spend weeks shopping around. From initial introduction to site visit was two weeks. From kick-off to full compliance: seven.
The brief wasn't only to file a compliant report — it was to find the savings that mattered, even though the company is set to relocate to a new facility in 2026. We had to be ruthless about which findings made the cut, and which were noise.
Pre-analysis showed a clear bimodal pattern — letting us pinpoint plant that ran when nobody needed it.
Recurring 380 kW peaks tied to a single compressor regime. Small control change, big saving.
~90 kW continuous overnight load — heating controls and standby loads on 24/7 unnecessarily.
Largest single energy load on site. Control regime, leaks and pressure setpoints all in play.
Continuous extract and conditioning even outside production hours. Sequencing opportunity identified.
Set-points and time-clocks not aligned to the operational shift pattern — running outside need.
Mixed age estate, sub-optimal zoning in non-production areas, no daylight or occupancy linkage.
Behavioural and shift-handover changes that cost nothing, but reduce the persistent base load.
Integration of ESOS into the wider SECR reporting cycle to remove duplication and improve trust.
Compliance is the floor, not the ceiling. We sequence the work so the audit produces an Action Plan you can actually use — not a binder that goes in a drawer.
Before any site visit, we load 12 months of half-hour electrical data and identify biggest users, base load and the operational pattern. The site visit is targeted as a result.
First task on site: install temporary loggers on the biggest users so we can read the audit live, not in retrospect. Confirms or challenges the desk findings.
A thorough audit of all the processes, not just the obvious ones. The compressor and the paint line were obvious — the heating control and lighting weren't.
KAB are moving facility in 2026 — so we prioritised only the most practical findings with the quickest returns. No one funds a five-year payback on a building you're leaving.
We supported KAB through every step of the ESOS process — submission, Lead Assessor sign-off, regulator correspondence — until compliance was confirmed.
To be completely honest we were in a pickle with our ESOS submission. We needed an expert who could hit the ground running. Tenacious, detailed and an “energy geek” of the highest order — Kiro went straight to the heart of the matter. Truly a trusted partner for us going forward.
KAB's project started with a phone call when time was already short. If you're in the same position — or you just want to know whether you qualify — we'll tell you straight, on the call.