A structured approach to energy management

Thorn Lighting, part of the Zumtobel Group, employs around 600 people at its Spennymoor site. Facing rising utility costs, siloed energy data, and no structured system, Thorn wanted to make the facility “best in class” for energy efficiency. Beyond cost savings, leadership aimed to reduce carbon emissions, strengthen customer trust, and enhance reputation through industry-leading energy management.

• Rising utility costs eroding margins.
• Limited visibility, energy data siloed and retrospective.
• No structured energy management system in place.
• Increasing compliance pressures (ESOS, SECR, ISO).
• Need to engage staff across all levels to embed energy into everyday operations.

• Designed a continual energy reduction framework embedded into daily operations.
• Installed 150+ meters with cloud-based sub-metering for real-time visibility.
• Identified and optimised the Top 10 Significant Energy Users (SEUs).
• Introduced standard operating procedures, targeted audits, and reporting.
• Built a cross-functional Energy Team and delivered staff training.
• Supported Thorn’s ISO 50001 certification journey, with full compliance support.
• Created a repeatable model for wider Zumtobel Group sites.

“We recognised the need to take a more structured approach to energy management, and working with TEST Consulting, John Swallow became part of our team to ensure a rigorous and systematic process that delivered best-in-class results. We’re incredibly proud of our BSI certification and the recognition of being one of the first UK lighting manufacturers to achieve it gives us a real competitive edge.”