Using environmental data to improve productivity

Like many businesses and organisations, manufacturers are under pressure to drastically reduce their emissions as the UK pushes towards net zero. Just look at the Energy Savings Opportunity Scheme (ESOS), which requires companies to regularly audit energy consumption and carbon emissions.

In recent years, we’ve seen more companies adopting smart monitoring and building automation to help them comply with these ever-changing standards. However, this technology can also help signpost ways to improve the surrounding environment, such as identifying overheated spaces that could cause drowsiness or pinpointing areas with poor air circulation that may lead to a buildup of CO₂ and other pollutants.

What to monitor

Environmental monitoring requires a balance. On the one hand, manufacturers must be tracking enough parameters to generate an accurate picture of their facility. But on the other hand, sensors, gateways and other IoT technology can be expensive to install. Therefore, it’s important to focus on the high-impact metrics — those that directly impact energy performance, operational costs and overall productivity. 

When it comes to productivity, indoor air quality (IAQ) can be highly significant. Around 1.2 billion workdays are lost globally each year due to air pollution, which could reach 3.8 billion days by 2060, according Clean Air Fund. Employees breathing polluted air are far more likely to get sick and experience reduced cognitive performance  

Particulate matter, volatile organic compounds (VOCs) and the fumes released during production processes are all worthwhile areas to track. Once manufacturers have captured this data, they can be proactive in installing new filtration systems, so they can pre-empt any health risks. Operators may also want to observe CO2 levels, temperature and humidity as these can also impact cognitive function and response times.

Making data actionable

It’s not just about collecting this data. It’s also about how it’s used. Information can be gathered from various sources: ventilation systems, HVAC units and the building management system (BMS). This data can help establish a performance baseline, but it’s often fragmented and unusable unless consolidated into a single, intelligent platform.  

Building functions can be integrated seamlessly into automation infrastructure. For example, Beckhoff’s TwinCAT suite of automation tools can transform almost any PC-based system into a powerful real-time control platform for building services. Manufacturers and facilities managers can collect and act on data from environmental sensors, occupancy detectors and energy meters alongside their standard control logic. If CO₂ levels rise, for instance, a smart system may respond by increasing the flow of fresh air, improving air quality in that area. 

By maintaining optimal environmental conditions, manufacturers can work proactively to reduce staff fatigue, improve concentration and boost overall productivity, particularly in facilities where precision tasks and long shifts are involved.

As the CBI’s report shows, UK manufacturing output has declined slightly in recent months, but improving conditions in facilities could play a part in closing this production gap. It all starts with maintaining a healthy, comfortable environment that staff can thrive in, which means staying on top of environmental inputs. However, it’s not just about tracking metrics like air quality. It’s about bringing data together and making it usable.

Find out more about how building automation can help you deliver on your company’s goals, download Beckhoff’s white paper on Solutions for energy-saving building automation. 

Karl Walker is market development manager at Beckhoff UK

www.beckhoff.com