TCP powers up sustainable hydrogen batteries with NAAME support

When TCP Group, based in Essex, were looking for a local manufacturing company to help with product development, they turned to James Williamson at NAAME for advice. He was able to recommend three members from the East of England with the necessary engineering skills. Now TCP’s new battery boxes are helping power their customers’ welfare units, alongside innovative, eco-friendly, hydrogen fuel-cell generators.

Taylor Construction Plant (TCP) focuses on supplying industry with specialist construction, plant, and compaction equipment. It has an extensive range from leading brands for hire or sale, as well as its own products, including its award-winning mobile, off-grid lighting towers. The company, which has been headquartered in Maldon for 35 years, serves UK and overseas customers from depots in Essex, Coventry, Leeds, Exeter, and Scotland.

“Our first contact with NAAME was only in October 2022,” explains TCP’s Operations & Development Director, Jim Irvine. “That’s when we received an invitation from James Williamson to give a short presentation about our hydrogen powered products to local business leaders in their Greater Ipswich Manufacturing Group. At the time we didn’t realise just how useful James’s knowledge of the region’s advanced engineering businesses would be in our next stage of development.”

TCP has a history of developing its own products, starting with a range of efficient diesel-powered, LED lighting towers, that cut fuel use by 75%. As well as providing its customers with better equipment, these developments also help reduce the seasonality of its business, complimenting TCP’s existing range of remote-controlled compaction equipment.

“About 10 years ago our MD, Andrew Barker, was inspired to look for sustainable alternatives to diesel to help our customers cut their carbon emissions. We thought of using batteries, but they did not give us the operating time we needed. Instead, we opted for emissions-free hydrogen fuel-cells from BOC, which were then in the early stages of industrial development. As a result, we pioneered ‘Ecolites’, the world’s first low-energy LED lighting towers powered by hydrogen fuel-cells.”

A modern technology whose time has come

Many people still think of hydrogen fuel-cells in terms of prototypes and demonstration products. Jim finds that amazing because “even five years ago we already had nearly 100 units available for hire. We now have around 450 LED lighting towers running on hydrogen, with more in production. Our TH200 model was even a finalist in the Highways UK 2017 Intelligent Infrastructure Challenge.”

As Jim explains, “Our Ecolites are ideal for any business that needs silent running lighting with zero emissions. Our customers range from operators on major infrastructure projects, such as HS2, to film production companies and events such as festivals and carnivals. They are particularly suited to construction or demolition projects that must comply with Section 61 of the Control of Pollution Act 1974, which requires contractors to minimise the impact of noise and vibrations on neighbours.”

TCP are still the only supplier of hydrogen-powered lighting towers in the UK, partly because they handle the hydrogen for their customers. “We use telematics for remote monitoring of all Ecolites, so we know when they need refuelling. This, along with them being far more reliable and lower maintenance than diesel powered units, gives our customers peace of mind.

TCP’s own engineers build the lighting towers and integrate the fuel-cells and LEDs with them. Even in this process, they are conscious of the need to reduce waste and pollution. “We are expanding our hydrogen powered fleet by retrofitting our old diesel lighting towers,” says Jim.

“That enables us to reuse 50- 70% of the materials in the old towers, while responsibly recycling all the old diesel parts, such as the engine and fuel tanks. By upgrading to hydrogen while keeping the tower structure and chassis, we effectively add 10+ years to the life of the product. That makes good business and environmental sense – and is another reason why our customers choose us.”

Partnering for growth

TCP’s focus is on developing, deploying, and operating its products. It does not want to become a full-scale manufacturer of complex machinery. That is why it needed a trusted partner for its next product.

“We are committed to developing a safe, quiet range of hydrogen powered equipment that helps industrial customers reduce power consumption and carbon emissions” says Jim. “About two years ago we started looking at supplying zero emissions power packs for welfare units (tea huts), which could store excess energy produced by the hydrogen fuel-cells for later use. Unlike traditional generators, there is no environmental risk of fuel spillage with our hydrogen fuel-cell and ‘battery box’.

“Initially we built our own small-scale prototypes, which proved a success with customers. However, the market has significant growth potential, and we needed a reliable manufacturing partner to help us scale up production. That’s when we approached James Williamson at NAAME again because we wanted to support the local supply chain, rather than sending work outside the region.”

The value of the NAAME network

“The help we got from NAAME was invaluable as you can’t simply Google such specialists in your local area. James is like your personal search engine, with a detailed knowledge of advanced manufacturing and engineering businesses across the East of England. He had a good understanding of what we did and what we were looking for – making him the obvious ‘go-to’ contact. He also reacted speedily to our request for help, making three confidential introductions within about an hour of our initial call.”

After competitive pitches from all three companies, Jim selected one for the initial contract. “We were delighted with the result, as they had an excellent team capable of manufacturing machines with complex electronic components. They also suggested design improvements that would make the manufacturing process more efficient and shared our commitment to sustainability.”

The new TCP Eco Powerpack 60K (in bright yellow) is now available for hire alongside the Eco GH4 hydrogen fuel-cell power unit (in bright blue). TCP can also combine these units with solar panels for additional security of power supply – and to reduce the use of hydrogen gas. If you are looking for quiet, clean, compact power sources and lighting for your operations, take a look at the TCP range here

Jim is now quick to recommend NAAME to his contacts. “It’s an excellent business support group because the team know their region and the businesses in it. They take the initiative to pull people together, which is an essential activity that you can’t just leave to individual businesses. James Williamson is also a good intermediary who is confident about introducing businesses to each other.”

Find out more about NAAME here

You can register for your NAAME Membership here

Or contact James Williamson (james.williamson@naame.co.uk) for a confidential discussion about how NAAME can help your manufacturing business.