Smart steam controls cut aerospace plant energy use by 25%

A Portsmouth aerospace manufacturer has reduced energy consumption by approximately 25% after automating steam shutoff across its production equipment. The control upgrade prevents steam loss during idle periods, delivered a return on investment within months, and offers a practical model for facilities pursuing measurable efficiency improvements alongside LED lighting upgrades.

Key takeaways

The project demonstrates how targeted automation can deliver substantial savings without disrupting production. Key points include:

• Automated shutoff reduced steam energy use by about 25% year over year.

• The system closes steam lines at 6 p.m. while allowing operators to reactivate individual machines.

• Installation during a planned shutdown limited operational disruption.

• The early savings supported a rapid return on investment.

For contractors and facility managers, the broader lesson is clear: energy audits should examine both major equipment and the operating conditions around it.

Idle equipment created a significant energy opportunity

The manufacturer operates 21 steam-driven presses and spreaders used to form rubber and polymer components for aircraft systems. Production is specialized and generally takes place during the day, while some machines may remain unused for more than 24 hours.

Despite this operating pattern, steam often continued flowing when equipment was idle. Manual valves were difficult to operate, and some were located in areas that required working at height. These practical barriers made routine shutdowns time-consuming and inconsistent.

Centralized controls simplified operation

The upgraded system uses an automated angle-seat valve on each machine, with pneumatic switching managed from a centrally located valve island. An HMI touchscreen allows operators to control individual steam lines, while programmed scheduling closes all lines at the end of each workday.

The design also allows machines to be turned back on individually at the beginning of a shift. Centralizing the pneumatic controls reduced installation complexity and created a simpler maintenance path than fitting a separate control head to every valve.

Measured savings validated the investment

The system was installed during the 2024 Christmas shutdown and commissioned in January 2025. After 12 months, energy savings were approximately 25% on a month-by-month basis compared with the previous three years, when production levels were broadly comparable. Savings recorded during the first half of 2025 indicated that the investment was recovered quickly.

Using comparable historical performance as a baseline is important. It gives facility teams a credible way to separate genuine efficiency gains from changes in production volume or operating schedules.

Controls and lighting can work together

Steam automation is only one part of a wider facility-efficiency strategy. Commercial and industrial sites can also reduce electrical demand by upgrading high-use areas with professional LED fixtures and occupancy or scheduling controls. Led Lumenaires supports contractors and property managers with spec-ready SKUs, bulk availability, fast fulfillment, and assistance with layouts, rebates, and large quotes.

The same operating principle applies to both systems: deliver energy only when and where it is needed. Combining equipment controls with efficient lighting can improve operating costs, visibility, and maintenance planning without requiring a wholesale change to production processes.

A repeatable model for industrial facilities

The Portsmouth project highlights a repeatable approach: identify equipment that operates outside production hours, remove the manual barriers to shutdown, automate control, and measure results against a reliable baseline. Planned maintenance windows can further reduce installation risk.

For facilities evaluating upgrades, the most effective projects may not always involve replacing major machinery. Targeted controls, paired with efficient LED lighting and professional project support, can produce measurable savings while preserving the flexibility that operations require.

Sources

• Control upgrade delivers 25% energy savings, Plant & Works Engineering.