Coats saves $630K on energy bills with MRI Energy
Coats is a global leader in the manufacturing of threads and structural components for apparel and footwear, creating a wide range of performance materials and other products across an extensive industrial portfolio comprising over 50 sites worldwide.
Senior Engineering Manager Ray Smith has been responsible for spearheading two critical projects for Coats: energy intensity and water recycling, both tasked with realizing ambitious performance targets by 2026. From his experience working for major global food businesses, Ray saw the opportunity to leverage real-time data to not only drive cost savings but also unleash newfound potential for productivity and collaboration.
Empowering with MRI Energy
Coats leveraged MRI Energy to revolutionize their approach to energy and water management across 12 of their sites and looking to expand the scope with 9 more sites. The platform’s dynamic data streaming capability was a game-changer, enabling swift, agile decision-making based on real-time insights. This agility proved instrumental in seizing opportunities quickly.
Ray Smith emphasizes, “MRI Energy is a one stop shop for a number of things. With MRI Energy, we have dynamic data streaming to our sites which gives us the opportunity to make very quick, agile decisions, reacting to changes in consumption and identifying opportunities in a much quicker and more reactive way, so we can respond faster.”
“We’ve been able to chase opportunities quickly without laborious manual data collection, spreadsheets or manual review processes. The project management side of MRI Energy also gives us the opportunity to present opportunities for projects that require capital investment, calculating paybacks easily. From a global sustainability point of view, we can ask early questions if things aren’t trending in the right direction, rather than waiting for reports and reacting too late. Our Sustainability Director can see real-time data on particular sites, and direct resources to where it looks like support is needed.”
Efficiency through Integration
Through MRI Energy, Coats achieved an unprecedented level of integration, with data from a range of meters and sensors streamed into the system in real-time. Configurable dashboards were tailored to suit departmental needs, providing managers with a nuanced view of their consumption patterns. This allowed for precise decision-making, ultimately driving operational efficiency.
“Some of our systems are very manual and people need to make decisions based on an LED readout”, explained Ray. “We want to integrate these into MRI Energy so that they receive an automated alarm rather than needing to check a screen regularly, which will allow us to reach more quickly.”
MRI Energy dashboards are used at all levels of the business, from Director to departmental level, offering the real-time data Coats’ team need to respond quickly to changes in performance or opportunities for improvement.
Business Impact
The impact of MRI Energy on Coats’ operations has been remarkable. In 2022, 146 priority targets were identified, resulting in staggering savings of $630,000 USD. Additionally, a global reduction of 22 million kilowatts was achieved across 12 sites. The journey continues in 2024, with plans to extend these initiatives across nine more sites.
Looking Ahead
Through MRI Energy, Coats has not only unlocked operational efficiencies but has also set a compelling precedent for the future of sustainable manufacturing, and Coats’ forward-thinking approach is set to redefine industry standards. The integration of real-time data analytics not only empowers decision-makers but also sets a precedent for agile, informed sustainability practices.
Ray Smith anticipates even deeper integration in the future. Discussions are underway to connect larger pieces of equipment, allowing for remote support and data export. Additionally, there are ambitious plans to incorporate air emissions data into MRI Energy, further bolstering Coats’ environmental compliance efforts.
Ray Smith reflects on this journey, “It’s really important that people understand the value of having dynamic data. As a manufacturing organisation, you quickly find yourself behind the curve if you’re not accessing dynamic data at every level, and as an energy-intensive business it’s critically important to reach quickly to change. In 35 years the difference I’ve seen is incredible – technology like MRI Energy is allowing us to move much quicker to respond to what we need to as a business.”