FISC is working with industry to help solve problems relating to six key themes. In this case study partner CPI is supporting a leading manufacturer to make use of their existing data, optimise operations and reduce energy use and scrap.

Theme: Process Optimisation
To work closely with industry to develop sensing and measuring approaches that improve the efficiency of exiting processes and help develop new processes. Data gathered will be analysed to help improve operations, but also to identify best practice across the foundation industries and transfer knowledge that aids the competitiveness of the UK.

What problem/s does industry have?
Industry wants and needs to decarbonise but is unsure how digitalisation can help their operations and reduce energy use, wastage and lower carbon emissions. For many businesses the cost, time and skills required can be too great to implement without a clear sense of return on investment (ROI).

How is FISC helping solve the problem?
Through collaboration FISC and its partner CPI worked with Zentia, a leading manufacturer of high-performance ceiling tiles and floating ceilings for the construction market, to make better use of their data.

Based in Gateshead, Tyne and Wear, Zentia saw huge potential in making use of their existing data to optimise their dryer operation and reduce energy usage and scrap.

By analysing existing data from sensor readings in the 100m dryer used to manufacture the tiles alongside manual measurements CPI cleaned and processed thousands of data points. The team then worked with Zentia to explore the data for hidden information about critical measurements not being used and built a proof-of-concept model to predict different operating conditions.

In future it may lead to an optimisation tool allowing Zentia to run their dryer predictively at the lowest possible temperate and the highest possible speed which has the potential to deliver huge cost savings by reducing the fuel consumption and scrappage rates.

"The work with FISC through CPI has provided useful insights into the relationship between our existing Quality Control measures and the drying process that we will use to further our understanding and reduce the energy used to dry our tiles." Gavin Scott, Technical Manager (Zentia).

How does this benefit industry?
Digitalisation allows industry to optimise their existing equipment and processes to deliver the maximum efficiency and productivity.

Research like this proves the value in existing data and how it can be explored and modelled resulting in proven success in reducing costs, wastage and carbon emissions. It also proves the effectiveness of available sensors available at lower cost that can improve process control and reduce carbon.

Read more case studies of CPI's work in innovation HERE.

If you'd like FISC to support you with your industrial problems please drop us an email at info@ukfisc.org

Published: 13-03-2025