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Engineering for Efficiency: Turning Energy Pressure into Opportunity UK industry continues to operate against significant economic headwinds, with high energy prices, increasing operating costs, strict regulatory requirements, geopolitical uncertainty and growing competition from emerging markets all placing pressure on margins. Within this context, energy consumption has become a critical factor in determining profitability and, in some cases, the ongoing viability of manufacturing operations. The Hidden Opportunity in Legacy Plant Much of the UK’s manufacturing base relies on established or legacy plant, designed and built when energy costs were lower and the commercial case for efficiency improvements was less compelling. As energy costs have risen, that calculation has changed. Well-targeted energy efficiency projects can now deliver meaningful long-term savings, improve operational resilience and strengthen business performance. Faster Payback. Stronger Margins. For many manufacturers, improving energy efficiency is now one of the most practical ways to protect and enhance operating margins. Projects that may once have been difficult to justify can now achieve significantly shorter payback periods, particularly where opportunities exist for heat recovery, improved process control, reduced steam and utility demand, optimised equipment operation, or targeted upgrades to existing assets. Engineering That Delivers Measurable Savings Otto Simon Ltd has a strong track record in integrating beneficial technologies into established industrial processes, helping clients improve efficiency and reduce operating costs. Our multidisciplinary engineering team works closely with clients to understand their processes, constraints and commercial objectives, identifying where engineering effort can be most effectively applied to deliver measurable energy and cost savings. From Opportunity to Operational Benefit Whether designing a complex heat integration network for a new build facility, assessing utility demand across an existing site, or delivering simple, cost-effective improvements to operational assets, OSL supports clients from initial opportunity identification through to project execution. Our focus is on pragmatic engineering solutions that can be implemented safely, efficiently and with a clear understanding of return on investment. Start with a Focused Energy Review Based on the conversations we continue to have with clients across process and manufacturing sectors, there is significant opportunity to reduce energy consumption, improve asset performance and deliver immediate and long-term operational benefits. In many cases, the first step is a focused review of current plant performance to identify realistic, prioritised opportunities for improvement. Ready to Find Your Energy Savings?  If you would like to understand where energy savings may be available within your facility, or discuss how targeted engineering improvements could support your business, please contact us at eng@ottosimon.co.uk to discuss the opportunity for us to undertake an energy survey of your plant.

The Employee Council hosted a successful potluck lunch with the team at United House, and it is fair to say the whole event was very well constructed. All staff members contributed to a diverse and extensive buffet of food, leaving us all slightly slower-moving, and a little tired afterwards. Dishes on offer included jerk pulled pork, chilli con carne, homemade focaccia, flapjacks and an array of meats, cheeses and fruit, all washed down with (non-alcoholic) beer and G&T. The spread had clearly been designed with generous safety factors in mind, and by the end we were all operating somewhere outside our normal design capacity. It’s important as an Employee Owned Trust to build strong working and personal relationships with our colleagues, and nothing helps strengthen these bonds quite like breaking focaccia with the rest of the team. Based on this strong turn out, we are keen to repeat the process next quarter, albeit hopefully with the catering slightly better calibrated to the team’s calorific requirements and without such significant overage. That said, having a little redundancy in the system is rarely a bad thing, particularly when the redundant item happens to be flapjacks. A huge thank you all those that made and bought food, and especially to Anna, our EOT President and Office Manager, for all the hard work, organisation and no doubt a fair amount of stress involved in arranging the event and chasing up various people to ensure we didn’t all bring crisps with no dips. Her project management kept everything on programme, avoided any major snack-based clashes, and ensured the final delivery was both structurally sound and thoroughly enjoyed.

Otto Simon Ltd are proud to announce that we have achieved Cyber Essentials Plus certification

Stress awareness has never been more important in the modern workplace. Research consistently shows that one in four workers report feeling unable to cope with stress at work, a statistic that highlights a growing and genuine challenge for organisations and individuals alike. At Otto Simon, stress awareness is taken seriously, not only because it impacts productivity, safety and performance, but because people matter. As a business that works in engineering, we understand the concept of stress in more than one context. Pipework and mechanical structures subjected to undue loads can cause material to deform, yield and eventually fail. Like these materials, people too, if exposed to significant and persistent stresses may cause detrimental impacts to our mental health. Unfortunately unlike steel structures, where the capacity of materials and force they are subjected to can be modelled and calculated, the stresses being put on our mental wellbeing are often multiple and nebulous and there is no clear “Youngs Modulus” or “Yield Point” equivalent to our individual resistance and specific response to different stresses. By making this distinction clear, we recognises that people are not components to be pushed until failure. Instead, they are individuals who need understanding, empathy and appropriate support, especially when stress levels begin to build. Stress does not always originate from the job itself. Financial worries, concerns for family and friends, exposure to distressing news, and uncertainty about the future can all impact concentration, mood and resilience at work. Acknowledging this reality is essential. At Otto Simon, there is a clear understanding that stress may arise from both professional and personal circumstances, and support should not be limited solely to issues that occur “on the clock”. We believe strongly in watching out for our colleagues; As part of this commitment, Otto Simon has invested in training two Mental Health First Aiders, reinforcing the message that mental wellbeing is valued just as highly as physical health and safety. These trained individuals act as a first point of contact for colleagues who may be experiencing emotional distress, offering a safe, confidential and non‑judgemental space to talk. Mental Health First Aiders are not therapists, nor are they expected to “fix” problems. Instead, they serve as a vital bridge, listening, providing reassurance, and signposting individuals towards appropriate professional support where needed. By embedding this support within the workplace, Otto Simon continues to foster a culture where conversations about mental health are normalised rather than avoided. A mentally healthy workforce is a safer, more resilient and more effective one. High levels of stress can lead to fatigue, distraction and anxiety, increasing the risk of errors and workplace accidents. Conversely, we believe that when employees feel supported and able to talk openly, they are more likely to seek help early, before stress becomes overwhelming. Stress Awareness is not confined to a single week or campaign, it is an ongoing commitment. Through investment in people, open conversations, and practical support, Otto Simon demonstrates that wellbeing is a shared responsibility. Whether stress originates from within the business or from the wider world beyond it, no one is expected to face it alone.

Process and chemical industries deliver innovation and value by applying rigorous engineering practices.

Well, another year is winding down, and what a year it’s been! Here at Otto Simon, we decided to celebrate all the hard work and dedication of our fantastic team with an evening of festive fun, delicious food, and a touch of wanderlust! A huge, heartfelt thank you goes out to Anna for orchestrating what was a truly splendid Christmas gathering. From the atmospheric lighting to the perfectly planned tapas, Anna, you outdid yourself. Our merry band descended upon Trunk Lounge in Bramhall, and it was fantastic to see such a great turnout, proving that even after a busy year, we still love spending time together! Now, every good story has a new chapter, and for one of our own, that chapter involves packing a very large suitcase! We had the pleasure of raising a glass (or several!) to Chris and his partner Lydia, who are embarking on an incredible year-long adventure, travelling the globe, we are not jealous at all. From all of us at Otto Simon, we wish Chris and Lydia the very best of luck on their incredible journey. We are all sure looking forward to reliving your amazing memories with you upon your return. We would like to end the year with sincere thanks to our Clients, Partners and Staff for all their efforts over the past year and are looking forward to another busy and rewarding year in 2026. Here's to a wonderful Christmas break for everyone, and a prosperous, exciting New Year!

This year we celebrated our year of successes and lessons learnt at the Stanneylands, Wilmslow. Topics included how we have streamlined our, reducing business overheads and making our collaboration more efficient. Specific attention was paid to the successes of the projects we have delivered over the last year and the consolidation of the team into our new headquarters. Ferrostatics proudly shared their highest year of revenue and strong performance, with a promising year to follow. We have also reviewed key team changes, including the expansion of the engineering team and restructuring of our Sales team. We look ahead to 2026 with confidence, fresh focus and further passion to deliver leading engineering expertise and customer service!

Aerbio and Otto Simon have been jointly shortlisted as finalists for the IChemE Global Awards 2025 in the Biopharma category. Our entry, Clean Protein: Engineered for a Resource-Constrained World, showcases the research and engineering efforts being the development of Proton™, a protein-rich single-cell biomass produced using a novel aerobic gas-fermentation process, utilising hydrogen, oxygen, and carbon dioxide as feed gases. This project has demonstrated the feasibility of producing a sustainable, high-quality protein ingredient at pilot scale, with applications in aquaculture and animal nutrition today, and the potential to expand to food-grade applications in the future. The technical challenges of this work have been considerable. Designing and operating a continuous fermentation system with hydrogen and oxygen in flammable ranges required rigorous safety engineering: hazard studies, CFD modelling, ATEX compliance, and functional safety analysis were all critical. With no commercial-scale precedents to draw upon, designs were developed from first principles and validated through lab-scale experimentation and pilot-plant data. Despite the added complexity of international collaboration during the COVID-19 pandemic, the project successfully delivered a first-of-a-kind pilot facility, generating essential data to enable scale-up to demonstration and commercial scale. The outcome speak for itself: Proton™ contains over 70% protein with a complete amino acid profile, delivers strong results in digestibility and extrusion trials, and has already shown positive performance in aquaculture and poultry feed applications. It can be produced with a fraction of the greenhouse gas emissions and water use of conventional proteins, while requiring no arable land and supporting biodiversity by reducing reliance on fishmeal and soy. This nomination recognises the strength of our cross-disciplinary partnership, combining microbial fermentation expertise with advanced process design, safety engineering, and scale-up know-how. Together, we are laying the foundations for a scalable, climate-positive protein platform that can contribute to global food security while reducing environmental impact. We look forward to the awards ceremony later this year and to continuing our journey towards commercial deployment of this disruptive technology. Learn more about the project: - Aerbio website