Client Background
This manufacturer, well known for producing shower inserts, bathtubs, and similar products distributed through major home‑improvement retailers, had committed to cutting greenhouse gas emissions in half by 2030. At its Ontario, Canada location, leaders recognized the need for a practical plan that could guide the broader enterprise in meeting that target. The facility faced pressure to reduce operating costs, modernize aging HVAC systems, and identify immediate opportunities to improve efficiency without major capital expenditures. With corporate sustainability expectations rising and operational risks increasing, the site needed a roadmap that balanced ambition with financial responsibility.
Challenge
Before engaging Mantis, the facility lacked a cohesive approach to improving energy performance and reducing emissions. Energy decisions had been made incrementally over the years, leaving the site without a unified strategy or a clear understanding of which actions would yield the greatest impact. HVAC equipment had aged to the point where performance and reliability were increasingly uncertain, operating schedules were not optimized for true production needs, and several mechanical systems were consuming more energy than required. Without a detailed plan, the facility risked escalating costs, inefficiencies, and missed sustainability milestones.
Solution
Mantis delivered a comprehensive Performance Roadmapping engagement designed to clarify the site’s current state and identify the most effective path forward. The process began with extensive data collection and in‑depth conversations with operational and maintenance stakeholders to establish a baseline of how equipment was used and where inefficiencies were occurring. A detailed on‑site assessment enabled the team to uncover more than $120,000 in low‑cost efficiency improvements that could be implemented by facility staff without major investment.
From there, Mantis developed targeted strategies that addressed both immediate savings and long‑term asset modernization. The team identified opportunities to reduce unnecessary equipment runtime on the plant floor, improve and recalibrate system controls, and eliminate energy waste caused by air‑compressor leaks. HVAC systems were evaluated for upgrade potential, and Mantis provided concept‑level recommendations for high‑efficiency replacements that would meaningfully support the organization’s emissions‑reduction goals. The outcome was a clear, actionable roadmap that linked operational improvements, mechanical upgrades, and capital planning into a cohesive, long‑term strategy.
Results & Impact
The Ontario facility emerged from the engagement with a sharply defined strategy that balanced immediate operational wins with long‑range planning. With more than $300,000 in annual savings identified and a realistic pathway to achieving a 30 percent reduction in emissions from 2024 levels, the organization now has the clarity needed to pursue its broader target of a 50 percent reduction by 2030. The discovery of substantial low‑cost improvements allowed the site to begin driving savings immediately. At the same time, the HVAC modernization plan put the company on a solid footing for future performance, reliability, and sustainability. By combining data‑driven insights with practical, actionable recommendations, Mantis positioned the manufacturer to meet its goals in a financially responsible and operationally achievable manner.