Performance Case Study: Putting a Sock in High Energy Bills at Falke (20%+ Savings & R600k Tariff Win)
The renowned sock manufacturer Falke partnered with Augos in Bellville South for a transformative energy management program. By using submetering to identify compressors (not manufacturing equipment) as the main energy users, Falke achieved sustained savings exceeding 20% against production. Furthermore, a strategic tariff migration with the City of Cape Town delivered an additional projected R600,000 in annual savings, demonstrating the dual power of data and financial optimization.
The Challenge: Unmasking the True Significant Energy Users
The journey to substantial energy savings at Falke began with the golden rule: "You cannot manage something if you're not measuring it." Augos' first step was establishing a comprehensive energy consumption baseline via submetering to accurately identify their Significant Energy Users (SEUs).
The data revealed a crucial insight: counterintuitively, the compressors—not the sock manufacturing equipment—were the primary energy consumers. Armed with this knowledge, the team moved beyond focusing on the most obvious equipment to target the true source of energy waste. Falke's success is defined by its Energy Performance Indicator (EnPI): pairs of socks per kWh. The Augos platform enables this sophisticated measurement against production, moving beyond simple cost tracking to provide a verifiable, long-term operational goal that drives continuous improvement.
The Augos Solution: The Operational Power of Data-Driven Changes
With the SEUs identified, Augos implemented a collaborative, data-driven energy management program. This involved small, non-capital adjustments that had measurable, significant impacts through compressed air optimization utilizing ultrasonic air leak detection to repair costly air leaks and optimizing compressor settings for peak efficiency.
The program focused on load management by shifting consumption loads to reduce wasteful usage during off-hours and strategically shifting to LED lighting. Fortnightly meetings with the client were held to measure progress against the EnPI and set realistic weekly goals, ensuring operational buy-in. The result was a sustained, verifiable energy cost savings exceeding 20% measured against production.
The Result: Tariff Optimisation—The R600,000 Discovery
Falke's energy efficiency journey was dramatically accelerated when the Augos platform's Tariff Analysis tool identified a massive financial opportunity hidden within their existing utility structure. The analysis quantified an opportunity for substantial savings by changing their electricity tariff structure with the City of Cape Town Municipality. Augos managed the entire tariff migration process on behalf of the client.
On the very first bill under the new structure, Falke realized savings of over R100,000. Accounting for seasonal tariff variations, their projected annual savings from the tariff change alone are estimated at around R600,000—demonstrating the dual power of combining operational efficiency (20%+ savings) with strategic tariff optimization.
Key Takeaways
Comprehensive submetering revealed compressors as the primary energy consumers, not the obvious manufacturing equipment
Energy Performance Indicators (EnPI) like "socks per kWh" provide meaningful, operational targets that drive continuous improvement
Combining operational efficiency (20%+ savings) with tariff optimization (R600k) delivers comprehensive cost reduction
Significant savings achieved through air leak detection, load management, and lighting—without major capital investment