Caro Group Energy Cost and Carbon Reduction Success

How Advantage Utilities Helped Caro Group Save £3.2 Million and Drive Carbon Reduction

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Overview

Caro Group is a leading manufacturer of construction industry products with applications in aerospace, defence, and flood defence. As a highly energy-intensive operation, managing power costs and reducing carbon emissions are critical to maintaining competitiveness and meeting customer sustainability requirements.

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The Challenge

Energy is one of Caro Group’s largest overheads, and incorrect procurement decisions could have been disastrous for the business. At the same time, the company faced growing pressure from customers to provide lower-carbon, more sustainable products.

• High and volatile energy costs put profitability at risk.
• The foundry needed a structured approach to its carbon reduction journey.
• Sustainability targets required innovation across procurement, processes, and operations.

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The Solution

Advantage Utilities has partnered with Caro Group for over 12 years, delivering long-term cost savings and carbon reduction strategies. 

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Key initiatives included:

Strategic Procurement: In 2009, Advantage advised Caro Group to lock into a five-year energy deal. This foresight delivered massive cost savings during a period of extreme market volatility, helping the company remain competitive while many foundries closed.

Carbon Reduction Initiatives: Advantage supported Caro Group with a broad range of sustainability measures, from shared driving schemes and waste reduction to low-powered machinery, LED lighting, and shifting foreign meetings to video conferencing.

Ongoing Expert Support: Advantage’s consultants, led by Greg and his team, provided knowledge and solutions before challenges escalated, ensuring compliance with regulations and unlocking further savings.

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The Results

• £3.2 million saved in energy costs through strategic procurement.
• Significant carbon reductions from operational changes, including energy efficiency upgrades and reduced travel emissions.
• Business resilience: While hundreds of foundries closed, Caro Group survived and thrived.
• Time and resource savings: Regulatory compliance managed seamlessly with minimal input required from Caro Group.

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Client Testimonial

"Greg is always there. He has a vast amount of knowledge, and it seems to me that whatever question we ask him, he has the answer. On the odd occasion where he doesn’t, one of his colleagues at Advantage always does. Advantage came to us with solutions before we even knew we had the problem. In a time where hundreds of foundries went bust, we managed to stay afloat — and Advantage brought us a saving of over £3.2 million."

— David Lowe, Group Managing Director, Caro Group