+100
Production sites worldwide
Turning an Energy Crisis into a €350 Million Opportunity
When energy costs surged fivefold across Europe, this global chemicals leader faced the potential shutdown of critical operations. Together, partner DB Energy and EFESO worked with the company’s in-house team to conduct rapid diagnostics across 11 production sites. The partnership identified 160 energy-saving opportunities, transforming an existential threat into sustainable operational advantage.
Chemicals
Operations Strategy and Transformation
Sustainability
Our Client
A diversified chemicals group operating globally with both specialty chemicals and commodity products portfolios. The company maintains a strong culture of operational excellence developed through long-standing continuous improvement initiatives. Its European operations represent critical production capacity for both regional and global markets, with heavy energy consumption integral to its manufacturing processes.
40%
Operations in Europe
+1K
Employees at largest site
2km²
Site coverage area
The Challenge
The war in Ukraine created an unprecedented energy crisis that threatened the viability of European chemical manufacturing operations.
- Fivefold cost increase: Energy prices in Europe rose dramatically due to the disruption of Russian gas supplies, creating immediate pressure on heavy energy-consuming production units
- Existential threat to European operations: The sudden cost surge posed the risk of potential shutdown for business units across multiple European countries, threatening both regional supply chains and global production capacity
- Complex energy infrastructure: The interconnected nature of production units with centralized energy departments required comprehensive analysis across multiple sites, to identify savings opportunities while maintaining operational continuity
Real Results Achieved Together
Comprehensive energy diagnostics transformed an immediate crisis into a structured improvement program across European operations. Working alongside site teams and engineering departments, the partnership delivered immediate relief through quick wins and long-term sustainability through major energy projects.
€350 M
Total savings identified
160
Energy-saving ideas generated
15%
CO2 emissions reduction
30
Quick win initiatives
Transformation Impact
- Implemented high-CapEx projects including steam condensate recovery and cogeneration plant turbine upgrades
- Achieved immediate cost relief through operational adjustments requiring minimal investment
- Enabled client's engineering department to continue with concept designs and diagnostics independently
Our Approach
The partnership combined EFESO’s operational excellence expertise with DB Energy’s specialized energy engineering capabilities, working closely with the in-house team.
The three-step approach began with energy walkthroughs, spending one to two days on-site analyzing energy balance and discussing findings with operators and engineers. S
elected opportunities moved to concept design phase, developing detailed feasibility studies and business cases. The engineering and construction phase followed, with projects implemented either by the client’s in-house engineering team or subcontracted to DB Energy.
Initial diagnostics at four production plants and the main energy department expanded to ten additional plants across different European countries.
The vendor-neutral engineering expertise from DB Energy enabled unbiased assessment of energy-saving opportunities, from small operational improvements to large capital expenditure projects.
Quick wins, including adjusting pump pressure levels and improving steam pipe insulation, delivered immediate savings to recover project costs rapidly.
Related Services
ESG pledges require embedded operational transformation. We deliver measurable impact through circular economy practices, carbon reduction programs, and sustainable value chain redesign.
Facing Similar Energy and Cost Challenges?
- Rising energy costs threatening your operational margins and production viability
- Transforming energy constraints into competitive advantage through systematic improvement
- Partner with us to identify and implement sustainable cost reduction opportunities
Discover More Clients Results
>98.5%
Delivery readiness level consistently maintained despite inflation, sustainability investments and 12% volume growth
Food & Beverage
An eight year journey hardwired a common way of thinking and working into the organization, enabling Bell Food Group to sustain delivery performance above 98.5% despite rising costs and market complexity.
+5–6%
EBITDA expected in 5 years
Life Sciences
EFESO supported a major cosmetics supplier in redesigning operations across six factories and optimizing the supply chain, targeting improved productivity and long-term profitability.
+25
Business cases initially identified
Consumer Goods and Luxury
Design and implementation of a 10-year strategy targeting 4% annual growth for a world-leading luxury group, focused on aligning operations.
+30%
OTIF improvement
Life Sciences
Reengineered Order Management processes for pharma services provider, achieving 30% OTIF improvement to 95% target.
-50%
Reduction in claims
Packaging
Global packaging manufacturer deploys WCOM™ across 24 plants, slashing claims and waste 50% while boosting productivity 30%.
+20%
Increase in global production capacity using the same plants
Life Sciences
Global cosmetics manufacturer implements WCOM™ across 29 plants, achieving 20% capacity gain and 70% OEE.
+8.3%
OEE increase in 3 months
Packaging
Board manufacturer increased production capacity through WCOM™ implementation, achieving 8.3% OEE improvement in three months.
+25
Percentage points Line OEE improvement at a key site within 6 months
Food & Beverage
An initiative that improved Line OEE by 25 percentage points and positioned the organization to recover a $15M investment within 18 months.