Marshalls (the UK’s leading hard landscaping manufacturer) produces a large range of value added paving products and part of the process requires the use of natural gas to cure products; during 2013 the site used over 5 million kWh of natural gas for heating.

Marshalls identified a project to reduce heat loss in one of Brookfoot’s manufacturing departments;

  • A number of holes for product entry and exit which meant cold air ingress
  • A mixer deck where hot air rises into and is not where required
  • A curing area would be difficult to completely seal

Marshalls had already assessed the cost of rebuilding the department which proved to be cost prohibitive. Westgate consulted with Marshalls and designed a Flexiwall® solution that would be able to partition the current production and curing areas without the need for redevelopment. The design, made from durable PVC panels and connected together with a unique v-overlap system was able to work with the existing building structure and proved to be much more cost effective then alternative building methods. The final design also included two Fastflex® fast acting doors to ensure product could be moved efficiently between the production and curing area.

“Westgate worked in partnership with Marshalls to tailor the design to meet the production requirements. The installation team were great and met all our health and safety requirements, as well as doing a very neat job.  The project has proven successful and we are pleased with energy savings so far, it is a great alternative when costs of major building renovation are prohibitive.”

Westgate’s initial design was comprehensive and met all the sites requirements, however production managers at Marshalls expressed concerns that the partition may slow forklift trucks and lead to bottlenecks in production. A time lapse video was produced to assess forklift truck movements between the two areas and it was established that the design and fast acting doors would not cause this issue.

Marshalls conducted a degree day analysis to normalise the data between the winter period before installation and the winter period after, and found considerable savings. The project is likely to payback in just over 3 years and save 44 tonnes of carbon dioxide emissions per year from the reduction in natural gas used on site.

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