Newby Group turns to BEAS to cut costs and improve efficiency
Published: 22 January 2026
Business overview
Newby Group, a leading group of UK-based casting companies serving marine, oil and gas, offshore drilling, automotive and defence sectors, is strengthening its commitment to sustainability as part of a wider strategy to reduce costs and energy consumption over the coming years.
Operating in an energy‑intensive manufacturing environment, the company has identified energy management as a key strategic priority for the next two to three years.
While labour and material costs have long been closely monitored, Newby Group recognised that energy usage had not historically been managed to the same degree. ‘Energy is a significant part of our operating costs, and we realised we needed a more structured and informed approach,’ Robert Heyworth, Managing Director at Newby Foundries said.
Support through the BEAS programme
Newby Group sought support through the Business Energy Advice Service (BEAS) programme, delivered in partnership with Aston University. Following initial contact, the company began an application process which led to an on-site energy audit conducted by sustainability consultancy ProEnviro.
The audit involved a detailed walkthrough of the foundry operations, during which specialists assessed how and where energy was being used and identified opportunities for improvement. The assessment highlighted several ‘low-hanging fruit’ opportunities, including addressing compressed air leaks, issues the business was already aware of but had not yet prioritised.
However, the process also introduced the company to more advanced solutions.
Investing in automated energy monitoring
One of the most significant outcomes of the audit was the recommendation to install an automated monitoring and targeting system. The system enables the business to monitor energy usage at machine level, offering detailed insight into operational performance and real-time consumption patterns.
‘It allows us to drill down into what the machines are actually doing,’ the company said. ‘That level of visibility is something we simply didn’t have before.’
Once fully embedded, Newby Group plans to review energy usage on a daily basis, using the system to analyse the previous day’s data and identify inefficiencies early.
From factory to shop floor
Beyond the technical benefits, Newby Group believes one of the biggest advantages of the new energy management system will be the impact on workforce behaviour.
The company expects the system to support a culture shift where energy efficiency becomes part of everyday operations rather than an afterthought.
Just changing how people think about energy and what they’re doing day to day can make a significant difference.
Having accurate data makes energy usage visible and encourages more responsible decision-making across the site.
Projected savings and ongoing Support
Newby Foundries, part of the wider Newby Group, is forecasting a 5% reduction in energy usage over the course of a year as a direct result of the improvements, a figure expected to translate into a significant financial saving.
ProEnviro has played a central role throughout the project, from conducting the initial energy assessment to supporting the funding application and liaising with contractors during installation. This included coordinating equipment shutdowns and minimising production downtime on site.
Looking ahead, ProEnviro will continue to support Newby Group by assisting with training and development, ensuring internal teams are confident in using and interpreting the energy management system effectively.
‘They’ve been key not just in installing the system, but in helping us build the internal capability to manage energy better long term,’ the company said.
As energy costs and sustainability pressures continue to rise across the manufacturing sector, Newby Group’s data-driven approach positions it to make informed decisions, reduce waste and improve competitiveness in the years ahead.
Can BEAS help your business?
BEAS is dedicated to helping businesses across the West Midlands. Whether you're an SME aiming to lower energy bills or adopt greener practices, BEAS can help.
Register today to start your journey towards cost savings and business growth. Don't miss out, spaces are limited!
Register now