In this case study, Simmtronic explores how it integrated smart technology into its manufacturing site and boosted its energy efficiency.
In recent years, companies are increasingly looking at retrofitting their existing facilities to enhance energy efficiency and integrate smart building technologies. Simmtronic, a leader in lighting control systems and smart building infrastructure, recently undertook a major refurbishment of its manufacturing site in Hoddesdon. This project has proven to be a resounding success, transforming the building into a modern, energy-efficient smart facility while maintaining day-to-day operations.
Why Simmtronic embarked on the retrofit
The primary goal behind the refurbishment was to modernise Simmtronic’s headquarters and manufacturing site by creating a smart building that would not only improve the work environment but also significantly reduce energy consumption.
By implementing a comprehensive smart infrastructure, the company aimed to achieve long-term savings and contribute to sustainability efforts. Simmtronic sought to create a space that optimised energy use, reduced operational costs, and improved workplace conditions – all while showcasing the possibilities of the very technology it develops and supplies.
This project demonstrates that retrofitting existing buildings can be a cost-effective solution for companies looking to modernise while reducing their environmental footprint.
Crafting a smart building
The centrepiece of the retrofit was the creation of a digital twin – a real-time, virtual representation of the physical building, powered by a web of sensors and automated systems.
By installing Simmtronic’s SPQ.7 environmental sensors, the building now continuously monitors key factors including CO2 levels, humidity, temperature, and even volatile organic compounds (VOCs). These sensors feed real-time data into the Building Management System (BMS), enabling automatic adjustments to optimise air quality, lighting, and energy consumption based on occupancy and environmental conditions.
One of the most exciting integrations was the Mechanical Ventilation with Heat Recovery (MVHR) system, which responds dynamically to indoor air quality metrics. When CO2 levels rise in an area, the system increases fresh air intake, ensuring optimal air quality without excessive energy use. This precision-driven approach ensures that energy is only used when and where it’s needed, dramatically reducing waste and wear on equipment.
The building’s smart lighting system further enhances its energy efficiency. Simmtronic’s occupancy sensors automatically switch off lights in unused areas, and daylight linking technology adjusts artificial lighting based on natural sunlight. This integration significantly cuts energy consumption while maintaining a bright, comfortable environment.
Perhaps one of the most impressive features is the integration of smart access control using HID readers, which allows employees to enter the building with a tap of their mobile phone via Apple Wallet. This system not only enhances security but also reduces the need for plastic ID cards, aligning with the project’s sustainability goals. The building’s smart infrastructure even controls corridor lighting based on entry points, adding another layer of energy efficiency.
Overcoming challenges
Like any ambitious project, the Simmtronic retrofit faced its share of challenges. One of the most significant was the inevitable scope creep – the expansion of the project’s objectives as new ideas and opportunities emerged.
Initially, the plan was to reuse much of the existing equipment. However, as the team saw the potential of modernising more deeply, they chose to upgrade and replace more systems than originally planned. This allowed for even greater efficiency and better integration, but it also required careful management to maintain the project’s momentum while the building remained operational.
Retrofitting a facility while keeping it operational is a significant challenge, but it was made possible through a collaborative effort. From the start, Simmtronic’s team of engineers, consultants, and contractors worked together to address the technical issues that arose.
One major challenge was integrating systems from different manufacturers, especially since the HVAC units were installed at different times and operated on various protocols. Fortunately, modern units reduce these inconsistencies.
The advantage of having isolated systems means that if one outdoor condenser fails, only a specific area is affected, allowing the rest of the building to stay fully functional. This is a crucial benefit. Despite these challenges, the team embraced the opportunity to streamline systems and ensure seamless communication between the different technologies.
As one engineer put it, “We were building the plane while flying it.” Even with the complexities, this adaptive, forward-thinking approach allowed the team to innovate as they went, ultimately creating a smarter and more efficient building than originally planned.
Creating an immediate impact and long-term savings
The results from the refurbishment have been impressive. The real-time data generated from the various sensors and control systems have already led to an approximate 15-20% reduction in energy consumption, a figure that could increase further during the winter months. This reduction has been achieved primarily by optimising plant and lighting systems, including the use of daylight linking to minimise artificial lighting in areas that receive natural sunlight.
Additionally, Simmtronic has noticed a significant improvement in workplace conditions for both office and manufacturing staff. Improved air quality, personalised lighting, and optimised workflows have resulted in a more comfortable and productive environment. This demonstrates that smart building retrofits can deliver tangible benefits beyond just energy savings.
What could have been done differently?
In retrospect, there are several areas where Simmtronic acknowledges that the project could have been more efficient. One of the key lessons learned is the potential benefits of gutting the entire building from the start rather than opting for a phased retrofit. This would have allowed for a more streamlined integration of systems and could have reduced the overall cost and complexity of the project, though it would have prevented or at least disturbed day-to-day operations.
Furthermore, the company realised that integrating fewer but more efficient systems would have been beneficial. Instead of having 20 different condensers scattered across the building, the entire facility could likely have run off just four condensers, simplifying the system and reducing maintenance costs.
The benefits of retrofitting
This project showcases the advantages of retrofitting older buildings with modern smart technologies. Not only does it lead to substantial energy savings, but it also creates a more efficient, comfortable, and future-proof environment for occupants.
By implementing smart sensors, lighting controls, and building management systems, companies can drastically reduce their energy consumption and carbon footprint while improving the quality of the workspace.
The lessons learned from Simmtronic’s retrofit demonstrate the importance of flexibility and collaboration in large-scale projects. While scope creep and technical challenges can complicate matters, the results clearly show that the benefits far outweigh the difficulties. Retrofitting is not just a technological upgrade but a sound financial decision, offering long-term savings and a more sustainable way to operate buildings.
As Simmtronic continues to monitor the performance of its refurbished site, they are already looking at future innovations such as energy storage systems and solar panels to drive energy costs even lower. With a commitment to sustainability and smart technology, Simmtronic is leading the way in showing how retrofitting can turn older facilities into high-performing, energy-efficient buildings of the future.