While retrofitting inverters in the old fans was possible, this would have been an expensive option and would not have delivered the desired improvements in energy efficiency. As a result, M&S decided to remove the existing belt-driven fan and motor assemblies within its air handling units and upgrade them with new energy-efficient, direct-drive EC plug fans. Sigma was commissioned to carry out the removal of the outdated equipment and install the replacements.
Overview
One of the UK’s best-loved brands, M&S is committed to reducing its impact on the environment by making its stores more energy efficient. From a business perspective, like all high street retailers in the UK, it has also been impacted by the steep rises in energy costs and sees improvements in energy efficiency as a way to mitigate these. The new technologies installed by Sigma would cut energy usage across the M&S estate while also ensuring that temperatures within the newly refurbished stores were adequately regulated.
The Brief
Sigma was commissioned to take M&S on the journey to improved efficiency by replacing over 200 fans across several of its stores. This involved removing the obsolete belt-driven fans and motor assemblies, delivering the new equipment to the various stores and installing it.
The project would involve collaboration with M&S, including with individual stores, and working closely with the equipment supplier.
The Challenge
This was an extensive transformation requiring work to be carried out on large numbers of air handling units across multiple sites. For this reason, a collaborative approach was required so that M&S and Sigma were fully aware of the process, stakeholders were kept up to date at all times and schedules could be coordinated to meet the needs of individual stores. The project required Sigma to overcome a number of challenges. These included:
Staff Training
As the new direct-drive EC plug fans were specially designed for M&S. Sigma worked closely with the equipment supplier to ensure mechanical and electrical engineers were fully trained to install them, in line with the manufacturer’s requirements.
Preventing Downtime
Sigma was fully aware of the impact of downtime at M&S and worked flexibly to avoid this. Where possible, we carried out the upgrades out of working hours. However, where it was necessary to operate during working hours, we worked in conjunction with stores to avoid turning the air supply off, ensuring that air movement was maintained and that business could continue without disruption.
Project Management
Sigma’s extensive experience in end-to-end project delivery has enabled us to develop a project management tool that delivers a seamless process from planning through to completion. The bespoke software provides our project managers and partners with detailed, photographic records, live progress reporting and 360-degree visibility throughout the project implementation process. In this instance, the tool helped us schedule the project in accordance with the needs of individual stores, allowed teams to quickly locate the air handling units within the store and ensured that engineers were fully equipped to remove old and install new equipment on arrival. As a result, delays were avoided and the work was completed effectively in a shorter timeframe, reducing disruption and keeping costs to a minimum.
Just-in-time Delivery
Sigma’s project management tool also enabled us to add value through just-in-time delivery. By coordinating the delivery of the new equipment so that it arrived at individual stores just in time for the installation to commence, we were able to ensure that it did not take up valuable warehouse space or get in the way of M&S employees carrying out their work. At the same time, this avoided the potential for new units to become damaged or lost prior to our arrival.
Sustainability
Sigma and M&S have shared values concerning sustainability and are committed to making a difference. While the installation of more energy-efficient air handling units will bring long-term reductions in M&S’ carbon emissions, this was not the only way that sustainability was built into the project. Sigma always seeks to reduce the environmental impact of its projects by implementing sustainable working practices, making use of renewable and recyclable resources, as well as through effective waste management and recycling. For this project, we carefully worked out product delivery and team travelling routes to minimise transport-related emissions and ensured that all the old equipment removed from the stores was responsibly disposed of, recycling where possible and with nothing going to landfill.
Outcome
M&S now have over 200 new fans operating across its stores, with a further 50 scheduled for installation during the rest of 2022. Compared to the belt-driven fan and motor assemblies, the new direct-drive EC plug fans provide the retailer with a number of benefits.
The fans’ increased energy efficiency has delivered important cost savings; they can run at variable speeds and provide better control across the whole system, ensuring desired temperatures can be maintained; and they always run at 100% efficiency with no effect on performance, regardless of external temperature or how busy the store.
This is the second major project Sigma has carried out for M&S after successfully conducting maintenance work on fire dampers across all its UK stores in 2021. We are proud of the success we have achieved in upgrading over 200 air handling units across many of its stores and of the benefits these bring to air quality, in-store comfort, energy efficiency and sustainability. M&S are once again very satisfied with our project management, our collaborative and transparent approach and the quality and effectiveness of our work.
