+70K
Employees
Achieving 20% Energy Savings in E-Cigarette Manufacturing
A global consumer goods company sought to accelerate its low-carbon transition within operations. Partnering with EFESO, the company analyzed energy consumption across e-cigarette manufacturing and packaging lines to identify optimization opportunities.
Industry: Consumer Goods and Luxury
Service: Sustainability
Our Client
A global consumer goods company specializing in tobacco and nicotine products, with a broad portfolio distributed across multiple international markets.
+175
Served markets
“The Zero Losses Model is an excellent work!
“
The Challenge
The company aimed to accelerate its low-carbon transition and strengthen sustainability practices within manufacturing operations.
- Operationalizing sustainability goals: Corporate Sustainable Development Goals required concrete actions within manufacturing operations.
- Energy consumption reduction: Need to identify significant opportunities to reduce energy consumption from manufacturing equipment and utilities.
- Future equipment standards: Establish energy saving targets for OEMs developing future production lines.
- Focused operational scope: The project targeted e-cigarette manufacturing and packaging departments within modern plants already running continuous improvement programs.
Real Results Achieved Together
The project delivered measurable improvements in energy efficiency and established a data-driven model to support sustainable operations.
20%
Energy saving in e-cigarette manufacturing
≈€500K
Savings identified per year
≈20%
Reduction of kWh per million units produced
Transformation Impact
- Implemented a “Zero Losses Model” using robust analytics to evaluate energy consumption per machine type.
- Identified savings opportunities across equipment consumption optimization, OEM solutions, and utilities optimization.
- Established a structured analytical approach to monitor machine energy usage during different operational states.
- Created a scalable methodology that can be replicated and rolled out across other plants.
Our Approach
EFESO collaborated closely with the client team to develop a structured analytical approach for understanding and reducing energy consumption in manufacturing operations.
- Energy Analytics Development
• Developed an analytics approach to model equipment energy consumption. - Data-Driven Consumption Analysis
• Modeled energy consumption per machine type, including operational status such as machine stoppages, normal production, and ramp-up or ramp-down phases. - Identification of Energy Saving Opportunities
• Identified significant opportunities to reduce energy consumption (kWh) per million units produced. - Scalable Methodology Design
• Designed an approach that can be easily replicated and rolled out to other plants.
Related Services
Sustainability
ESG pledges require embedded operational transformation. We deliver measurable impact through circular economy practices, carbon reduction programs, and sustainable value chain redesign.
Facing Similar Sustainability and Energy Efficiency Challenges?
- Seeking to reduce energy consumption in manufacturing operations.
- Looking to translate corporate sustainability goals into operational improvements.
- Wanting to identify scalable energy optimization opportunities across production sites.
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