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The final session in Priority One’s 2026 energy event series explored how businesses can reduce energy costs, improve operational efficiency and make better use of the energy they already consume.
With energy prices continuing to put pressure on businesses, speakers highlighted how relatively low-risk improvements, better use of data and smarter operational decisions can deliver significant savings without necessarily requiring major capital investment.
Bringing together practical examples from horticulture, refrigeration, manufacturing, commercial buildings and infrastructure, the session demonstrated how organisations are finding opportunities to reduce energy consumption, improve performance and strengthen their long-term energy resilience.
Attendees heard from speakers from Trevelyan’s, Maestro, Lawter, bTune by Beca and Fulton Hogan. Here we share key insights from the session, along with a recording of all presentations (video above).
Key takeaways
- Energy efficiency should be the first step before investing in new energy technologies or changing energy sources.
- Understanding where, when and how energy is being used is essential to identifying savings opportunities.
- Relatively simple operational changes can deliver significant financial and emissions reductions.
- Data monitoring, automation and optimisation tools can help businesses identify inefficiencies that would otherwise go unnoticed.
- Refrigeration, heating, ventilation and industrial process systems offer significant opportunities for energy savings.
- Collaboration with energy suppliers, technology providers and industry experts can help businesses develop and implement successful projects.
- Energy efficiency is an ongoing journey, requiring continuous monitoring, improvement and investment.
From Coolstores to Flex Markets: Practical Energy Optimisation in Action – Sarah Lei, Head of Strategic Projects, Trevelyan’s
Trevelyan’s is one of New Zealand’s largest post-harvest sites, packing around 10% of the country’s export kiwifruit and avocados. With five packhouses, 44 cool stores and annual electricity consumption of 15.7 GWh, energy is a significant operating cost for the Te Puke-based business. In 2025, Trevelyan’s spent approximately $3.6 million on electricity, highlighting the growing importance of energy efficiency to its long-term business strategy.
Sarah outlined how the business has taken a strategic approach to understanding its energy use, balancing operational requirements, electricity costs, carbon emissions and future growth.
One of the first initiatives was demand flexibility through automated load shedding. Once the cool stores are full and fruit temperatures are stable, Trevelyan’s can switch off evaporator fans for two to three hours during peak evening periods. With temperatures closely monitored, the system can quickly restart if required. This initiative has delivered $62,225 in electricity savings.
Trevelyan’s has also partnered with Simply Energy through its Simply Flex programme, allowing its cool stores to be switched off at short notice during periods of grid stress. In return, the business receives payments for providing flexibility, earning $51,187 over the previous 12 months.
Another significant investment is a new rooftop solar installation across packhouses two, three and four. With 1,224 solar panels, the system is expected to generate 900,000 kWh annually, covering approximately 6% of the site’s electricity requirements. The project represents an investment of approximately $800,000, with anticipated annual savings of $151,000 and a 5.6-year payback.
Looking ahead, Trevelyan’s is continuing to investigate further opportunities, including electrification of its forklift fleet, EV charging, additional solar, battery storage and more detailed monitoring of individual cool stores.
Things to consider:
- Automated load shedding can reduce electricity costs without compromising product quality.
- Demand response programmes can create additional revenue opportunities.
- Solar investments need to be matched to a business’s actual energy consumption profile.
- Detailed energy data is essential for understanding performance and building a business case.
- Older refrigeration infrastructure presents opportunities for future efficiency improvements.
Key insight: Energy efficiency doesn’t always require major investment. Trevelyan’s has already achieved meaningful savings through smarter operation of existing equipment, while building a longer-term strategy for solar, electrification and improved energy performance.
Optimising Cold Storage for Better Energy Performance – Adrian Dickison, Technical Fellow, Beca & Co-founder, Maestro
Adrian Dickson introduced Maestro, a machine learning tool designed to improve the efficiency of large refrigeration systems used across dairy plants, meat processors, cool stores and other industrial facilities.
The system uses an on-site machine learning algorithm and digital twin to continuously optimise refrigeration performance. It adjusts operating conditions every five seconds, identifying the most efficient way to deliver the required refrigeration while responding to changing loads and ambient temperatures.
Maestro also identifies equipment faults, inefficient operating practices and declining asset performance that can significantly increase electricity consumption.
Adrian highlighted the importance of compressor condition, explaining that older ammonia screw compressors can consume up to 65% more power than when they were new. While mechanical rebuilding may restore a compressor’s physical condition, it doesn’t necessarily restore its original energy efficiency.
He also shared an example following Cyclone Gabrielle, when a refrigeration plant in Hawke’s Bay experienced problems with water treatment in its evaporative condensers. The resulting condenser fouling increased total power consumption by 18%, demonstrating how operational issues can have a substantial impact on energy costs.
Other opportunities include improving chilled water and glycol systems, where poorly controlled pumps can circulate water unnecessarily and increase refrigeration energy consumption. One example highlighted an additional $100,000 in annual electricity costs from a single system.
Potential opportunities include:
- Continuous refrigeration system optimisation.
- Identifying inefficient compressor operation and equipment wear.
- Detecting condenser fouling and other maintenance issues.
- Improving chilled water and glycol system controls.
- Developing business cases for equipment replacement and upgrades.
Adrian reported that Maestro typically delivers energy savings of between 5% and 20%, depending on the refrigeration plant configuration.
Key insight: Refrigeration systems can hide significant energy inefficiencies that are difficult to identify through conventional monitoring. Continuous optimisation and better operational data can unlock savings while helping businesses identify where further investment is justified.
Turning Data into Action: Finding and Fixing Energy Inefficiencies – David Pugh, Process Automation Engineer, Lawter
David Pugh demonstrated how relatively affordable monitoring technology and data analytics can help manufacturers identify and address energy inefficiencies.
Lawter is a global bio-based specialty chemicals company operating a manufacturing facility at Mount Maunganui. Its products are derived primarily from pine-based by-products, supplying ingredients for a wide range of applications, including detergents, fragrances, adhesives, cosmetics and road marking products.
David explained how Lawter has introduced Internet of Things (IoT) sensors and TrendMiner software to improve visibility of its operations and identify opportunities to reduce energy consumption. One of the most significant opportunities was identified through an audit of the site’s steam and condensate system, undertaken with specialist company TLV.
The review uncovered several issues, including failed condensate traps, steam being piped directly into the condensate system and undersized condensate return lines. These inefficiencies were resulting in unnecessary steam consumption and poor system performance. Addressing these issues delivered estimated annual savings of $438,000.
Lawter then introduced IoT sensors to monitor condensate temperatures and identify future failures. By connecting this information to TrendMiner, the business can automatically detect when equipment is operating outside its expected range and alert maintenance teams before significant energy losses occur.
David also demonstrated how TrendMiner can analyse large volumes of operational data to identify relationships between different process variables, helping operators understand what is causing inefficiencies and equipment problems.
Importantly, the technology doesn’t have to be expensive. David highlighted examples of sensors costing approximately $350, compared with thousands of dollars for traditional monitoring equipment.
Things to consider:
- Low-cost sensors can provide valuable operational information without major infrastructure investment.
- Monitoring steam and condensate systems can uncover significant hidden energy losses.
- Automated alerts help ensure efficiency improvements are maintained.
- Data analytics can identify relationships between equipment performance and energy consumption.
- Working with specialist technology providers can help businesses implement cost-effective solutions.
Key insight: You don’t necessarily need expensive technology to make a meaningful difference. Affordable sensors, connected systems and effective data analysis can uncover substantial savings and help businesses maintain improvements over time.
Easy Energy Savings Through HVAC Optimisation – Ben Neilson, Senior Mechanical Engineer, BTune by Beca
Ben Nelson introduced bTune, an energy optimisation platform designed to improve the efficiency of commercial buildings, particularly heating, ventilation and air conditioning (HVAC) systems.
Originally developed within Beca, bTune is now a standalone business operating in New Zealand and the United States. The platform uses a small on-site computer and software to continuously monitor and optimise building systems. Rather than relying on artificial intelligence or machine learning, it uses established programming logic to make predictable, automated adjustments to building operations.
Ben reported that bTune typically delivers energy savings of between 10% and 30% of a building’s total energy consumption. He outlined a hierarchy of energy efficiency improvements, starting with the simplest opportunity: turning equipment off when it isn’t needed. Many commercial buildings continue running heating, cooling and ventilation systems overnight or outside normal occupancy hours simply because nobody is monitoring their operation. Further savings can come from adjusting temperature settings, reducing operating hours, optimising equipment speeds and improving how different heating and cooling systems work together.
Ben shared several examples of inefficiencies identified across commercial buildings, including:
- Unnecessary overnight operation: A large Auckland building was found to be running approximately half its systems throughout the night. The savings identified were worth more than bTune’s total initial engagement fee.
- Optimising start-up times: Buildings often start heating or cooling hours before occupants arrive, even when conditions don’t require it.
- Chilled water systems: Reducing pump pressure when full capacity isn’t needed can lower energy consumption.
- Cooling towers: Running multiple cooling towers at lower speeds can improve heat transfer while reducing fan energy.
- Temperature settings: Gradually adjusting office temperature set-points can reduce energy use without noticeably affecting occupant comfort.
Ben also highlighted opportunities for demand response, where buildings can temporarily reduce electricity consumption during periods of high grid demand in return for financial payments.
Things to consider:
- Turning equipment off when it isn’t needed is often the simplest energy-saving opportunity.
- Building data can reveal significant inefficiencies that would otherwise go unnoticed.
- Small operational adjustments can deliver substantial cumulative savings.
- Automated optimisation helps maintain improvements without constant manual intervention.
- Demand response can create additional revenue opportunities.
Key insight: Commercial buildings can waste significant energy through unnecessary operation and poorly optimised systems. Better monitoring and automated controls can unlock 10–30% energy savings, often without major capital investment or noticeable changes to building comfort.
Operations: Finding Opportunities for Better Performance – Aaron Gill, Executive Divisional Manager, Fulton Hogan
Aaron Gill shared how Fulton Hogan has improved energy efficiency at its Tauranga bitumen plant through better operational controls, data monitoring and supply chain optimisation.
Bitumen needs to be heated to remain liquid and pumpable, making storage and distribution energy-intensive processes. Traditionally, Fulton Hogan’s operations relied on large natural gas-fired heaters to maintain temperatures, while uninsulated storage tanks resulted in significant heat losses.
Aaron explained how the business has taken an incremental approach to improving performance, including installing a new insulated 10,000-tonne storage tank and introducing an automated PLC control system. Improved monitoring and data analysis have given the team greater visibility of temperatures, pump speeds and operating conditions, helping identify opportunities to reduce energy consumption.
A significant opportunity came from reviewing the way bitumen was sourced, stored and distributed. Previously, imported product was stored at Fulton Hogan’s Totara Street facility before being reheated and transferred to its Hewletts Road plant, creating unnecessary heat losses and additional gas consumption.
Following changes to its supply chain, including moving to a single bitumen grade sourced from Asia, Fulton Hogan has been able to make greater use of its insulated storage capacity and reduce unnecessary product transfers. This supply chain optimisation reduced gas emissions associated with the operation by 45%, saving approximately 900 tonnes of carbon and reducing associated energy costs.
Aaron also discussed the business’s investigation into electrifying its bitumen heating systems following uncertainty around future gas supply. A new 10-year gas supply agreement has allowed Fulton Hogan to take a longer-term approach, continuing to optimise existing operations while assessing emerging electric heating technologies.
Things to consider:
- Insulated storage tanks can significantly reduce heat losses and energy costs.
- Automation and better data monitoring help identify operational inefficiencies.
- Reviewing the entire supply chain can uncover savings beyond individual equipment upgrades.
- Reducing unnecessary product handling and reheating can deliver significant emissions reductions.
- Major electrification investments need to consider energy supply, infrastructure requirements and long-term costs.
Key insight: Significant energy savings don’t always come from investing in new technology. Fulton Hogan demonstrated how better operational controls, improved infrastructure and supply chain optimisation can reduce energy consumption and emissions, achieving a 45% reduction in gas emissions and saving approximately 900 tonnes of carbon.
To watch these speaker presentations, see the video at the top of this page.
This piece is part of an ongoing Priority One series focused on energy. We want to engage as many businesses as possible in our energy conversations – find out more here, and sign up to our newsletter featuring expert insights, opportunities and free events here.