Putting a sock in high energy bills at Falke.
The renowned sock manufacturer Falke partnered with Augos in Bellville South for a transformative energy management programme. Submetering revealed the compressors, not the manufacturing equipment, as the main energy users, and Falke achieved sustained savings exceeding 20% against production. A strategic tariff migration with the City of Cape Town delivered a further projected R600,000 in annual savings.
- Submetering revealed the compressors, not the manufacturing equipment, as Falke's biggest energy users.
- Small, non-capital changes cut energy cost by over 20%, measured against production.
- A tariff migration Augos managed with the City of Cape Town added around R600,000 in projected annual savings.
- Performance is tracked as pairs of socks per kWh, driving week-by-week improvement.
Unmasking the true significant energy users
The journey to substantial savings began with the golden rule: you cannot manage what you don't measure. Augos' first step was establishing a comprehensive energy consumption baseline through submetering, to accurately identify Falke's Significant Energy Users (SEUs).
The data revealed a crucial insight: counterintuitively, the compressors, not the sock-manufacturing equipment, were the primary energy consumers. Armed with this, the team moved past the obvious equipment and targeted the true source of energy waste.
Falke's success is measured in pairs of socks per kWh, its Energy Performance Indicator (EnPI). Measuring energy against production, rather than simple cost, gives a verifiable, long-term goal: week by week, more socks per unit of energy, and a real hedge against rising South African electricity costs.
The operational power of data-driven changes
With the SEUs identified, Augos ran a collaborative energy management programme of small, non-capital adjustments that carried measurable impact:
- Compressed-air optimisation: ultrasonic air-leak detection to repair costly leaks, and compressor settings tuned for peak efficiency.
- Load management: shifting consumption to cut wasteful off-hours usage, and a move to LED lighting.
- Continuous engagement: fortnightly reviews against the EnPI, setting realistic weekly goals and keeping operational buy-in.
The result was sustained, verifiable energy cost savings exceeding 20%, measured against production.
Tariff optimisation: the R600,000 discovery
Falke's efficiency journey accelerated when the Augos platform's tariff analysis surfaced a major financial opportunity hidden inside their existing utility structure. The analysis quantified substantial savings from changing their electricity tariff with the City of Cape Town, and Augos managed the entire migration on the client's behalf.
- Immediate win: on the very first bill under the new structure, Falke saved over R100,000.
- Projected annual saving: accounting for seasonal variation, the tariff change alone is estimated at around R600,000 a year.
What were the main energy consumers at Falke?
Submetering revealed that the compressors, not the sock-manufacturing equipment, were the primary energy users. Targeting them, rather than the obvious machinery, unlocked the savings.
How did Augos identify the compressors as the problem?
By establishing a comprehensive energy consumption baseline through submetering. That baseline pinpointed the site's Significant Energy Users (SEUs), which showed the compressors driving consumption rather than the production line.
What is a Significant Energy User (SEU)?
A plant or process that drives a meaningful share of a site's total consumption, such as a compressor, chiller, oven or production line. Identifying the true SEUs focuses effort where the cost actually sits, instead of on the most obvious equipment.
Did the savings require capital investment?
No. The savings exceeding 20% came from small, non-capital adjustments: ultrasonic air-leak detection and repairs, compressor settings tuned for efficiency, load shifting to cut off-hours usage, and a move to LED lighting.
How does Augos measure energy performance at Falke?
Against production, using an Energy Performance Indicator (EnPI) of pairs of socks per kWh. Measuring energy against output, rather than cost alone, gives a verifiable, long-term goal and drives week-by-week improvement.
How much did Falke save from the tariff change alone?
Over R100,000 on the very first bill under the new structure, with projected annual savings of around R600,000 from the tariff change alone, accounting for seasonal variation.
Did Augos handle the tariff migration?
Yes. The Augos platform's tariff analysis surfaced the opportunity, and Augos managed the entire migration with the City of Cape Town on Falke's behalf.
Could this approach work for another manufacturer?
Yes. The same method applies to any commercial or industrial site, whatever it produces: submetering to find the true SEUs, then re-pricing real usage against every available tariff.
Find savings like these on your own site.
Book a demo with one of our energy experts.