Manufacturing leaders tell us:
The result?
Missed opportunities worth tens of thousands annually, sustainability targets that feel impossible, and energy decisions made in the dark.
Cotopaxi Consultancy joined Spirax Group in 2022 and has been delivering results for more than fifteen years, with up to 30% energy savings and up to 40% water savings across sites, and ROI in 1 to 2 years.
We achieve this by uniting your site data with our expert insight in a partnership that works.
Metering, Monitoring & Targeting
Turnkey solution that enables real time visibility through custom telemetry and monitoring. Together we keep waste down.
Deep Dive Energy Assessment
On site, data led assessment with clear actions, expected savings, and time to payback. Together we make your system efficient.
Sustainability Masterplan
A tailored roadmap to net-zero with project by project feasibility and expected impact. Together we cut operational carbon.
Strata enables data-driven energy optimisation by centralising and analysing utility and process performance in real time. By providing visibility across operations, it supports the identification of efficiency opportunities and cost savings. Scalable and adaptable, Strata acts as the foundation for translating operational data into actionable insights that drive sustainable improvements.
Case studies
Across manufacturing, food processing, packaging, and consumer goods, Cotopaxi’s data-driven energy consultancy team using the Strata platform, is delivering measurable savings and operational resilience. These success cases showcase how fast action, smart insights, and targeted interventions are helping customers cut waste, boost efficiency, and accelerate their journey to net-zero.
Personal Care Manufacturing: 70% Water Reduction
Cotopaxi’s audit uncovered excessive water use caused by a valve left open for two years. With new water metering and Strata in place, the issue was resolved and consumption dropped sharply.
Result: 750,000 gallons saved per day, $32,000 in pumping costs avoided annually.
Food Manufacturing: £24K Annual Saving via Machine Shutdown Optimisation
Strata data revealed that heat recovery systems were left running during shutdowns. Adjusting control logic to fully power down equipment eliminated wasted energy.
Result: £24,000 annual electricity savings.
Food Manufacturing: £600K Annual Saving via Steam Optimisation
By throttling steam supply to fryers and steamers and installing additional metering, the manufacturer optimised fuel use without affecting product quality.
Result: 4,767 GJ/month fuel reduction, ~£600,000 annual savings.
Consumer Goods Processing: $15.6K Annual Saving via Valve Repair
Steam metering identified faulty isolation valves leaking steam during downtime. Replacing the valves stopped losses and improved control.
Result: $15,600 in annual savings.
Food Processing: $87.6K Annual Saving via Water Leak Detection
Strata alarms flagged a sudden spike in water consumption. Repairs to leaks, bypass valves and solenoid seals quickly restored normal use.
Result: 8.76 million gallons saved annually, $87,600 cost reduction.
Your challenges become our focus:
For Site Energy Managers
- Cut energy costs while protecting production quality
- Meet sustainability targets with confidence
- Unlock savings in water, electricity, and gas
For Corporate Sustainability Leaders
- Benchmark performance across multiple sites
- Access reliable data to create fast, trusted ESG reports
- Define a clear pathway towards net zero and ISO 50001
Savings made:
Tired of dashboards that do not help
Reports that go nowhere. Cost pressure rising. Not sure where to start. Tell us your challenge and we will show you the first practical steps.
What you get from a consultation
- A quick review of your site context and constraints
- Clear next actions with expected impact and time to payback
- Honest advice on what to do now and what can wait
Book a consultation
