Understanding the Tips and Techniques in Reduction of Industrial Energy Costs

The unprecedented consumption of energy by the industries has sparked concerns all across the globe. The governments have asked companies to lower their usage while implementing stringent laws in place. The energy efficiency for industry has emerged as a major path to reduce both operations along with manufacturing costs and hence has worked out for all paradigms for the society.

Here are some of the basic techniques to help companies lower down the cost on account of energy consumption.

1. Develop an Energy Management Team

The primary task while looking for energy efficiency is to create a team that can carry out a massive energy audit. These individuals must know the ins and outs of the company and what works and what does not. Try to build a team only from the company itself as they understand the company and its requirements. This, in turn, will help them have a clear picture of the entire energy flow and the recommendations for the same as well.

2. Use the Machines Strategically

The next step in the process is to use the study the energy audit and craft plans accordingly. Schedule your machines accordingly. This can be synced up and hence should be considered for optimal use. On the other hand, identify the chief machinery that consumes the maximum energy. Avoid them using them during peak hours, if possible. Statically, this can save you 30 percent of the utility bill.

On the other hand, if possible, make sure to run the heavy machinery other than peak hours to get the best results.

3. Schedule Startups and Shutdowns

If your machines need to run 24×7, this is not for you. A lot many manufacturing units work in shifts, and this allows the machines to have some free time and save electricity during the period. This can reduce the costs substantially, and hence the experts in energy efficiency for industry recommend turning off every individual machinery during the period. On the other hand, make sure to turn on the entire setup only after having the right equipment to avoid spikes. If things go well, then you would be saving substantially in the process. To add on top of it, one can also avoid running heavy machinery during the peak hours to reach the highest point in optimization. These techniques will help you in the long run.

Read: A Detailed Overview on Energy Efficiency for Industry and the Future of Energy

4. Optimize the Air Compressors

The industrial air compressors form a crucial part of the factories as certain elements need to be prepared under the right temperatures. However, not many would understand that this important factor consumes electricity like any other and also gets wasted in the process.

In a survey, it was found that faulty air conditioners cost around $3.2 billion in the United States alone. However, with the right steps and regular maintenance, the device should show optimal results and hence should not be ignored at all costs.

5. Conduct an HVAC System Audit

As per the statistics, the HVAC systems consume more than 52 percent of the building’s energy requirements. This makes the HVAC system the single most system with the highest energy requirement. However, faults in the HVAC system can make the matter worse and hence is advised by the industry pundits to make sure to conduct HVAC audits at regular intervals to make sure that the energy efficiency for industry remains sane.

Here are three ways to make your HVAC system more efficient:

  • Install a programmable thermostat.
  • Regularly repair and insulate ducts to maintain energy consumption.
  • Invest in a demand-controlled ventilation system.

Digging Deeper into Elements of Energy Efficiency

However, despite these small tips and tricks, achieving high levels of efficiency is impossible without the rock-solid foundations. Here are some of the crucial steps in the process.

The Rise in Energy Awareness

The very basic step in the process of effective and efficient energy consumption is the rise in the level of awareness. It becomes the very duty of every other individual at the factory to work hard to save power. The following techniques need to be well documented as well using the WAGES (Water, Air, GAS, Electric, and Steam) facility.

Organizations need to spread the word at the individual level, while incentives and bonuses should be tied to the performance to boost performance. This also lays down the cornerstone for the ISO-50001 compliance framework for the plants too.

Some of the major facts about it are as following:

  • Treating energy consumption with an outside-in approach that is, looking at consumption within the facility and then move outward.
  • Accepting high energy bills as overhead.
  • Allocate energy costs evenly across certain measurable factors like square footage.

Read: Detailing the Various Aspects of Energy Efficiency for Industry

Facility Monitoring at Plants

It becomes the duty of the plants to know where most of the energy is consumed. Facilitators need to come up with models (even spreadsheet-based are accepted) to deduct crucial information about the plant. The companies with low energy usage should schedule production intelligently while the ones with high energy requirements should work with highly efficient equipment to make sure that the energy efficiency for the industry is maintained at all costs.

Automating Production

With the advancement in technology, a greater number of individuals have emerged to provide cost-effective and automated solutions. The same applies to the industries as well and hence could not be ignored at all costs. Allow the companies to automate the entire manufacturing process and detect abnormalities in the process. The integrated sensors make sure that they point out inefficiencies in the process while making adjustments of their own. This, in turn, would benefit the industry form multiple aspects, i.e., reduction in the manufacturing cost and automation of the equipment in the setup.

Controlling Production

However, despite the available solutions, several numbers of plants still operate in the dark. There is no advanced sensors or money-saving equipment to reduce production and operational costs. However, with a few simple steps, the following could be avoided. These are as follows:

  • Avoiding peak demand charges: Ramping of motors gradually to meet the demands.
  • Using the exact amount of energy to avoid extra costs. The following could be achieved by optimizing the power in relation to load.
  • Using highly intelligent solutions that can calibrate themselves without any external affairs.

Energy Optimization

Vitality use information at an item or SKU level offers new chances to improve vitality the executives, however, that by itself resembles driving a vehicle by glancing in the back view reflect. That view shows where you’ve been nevertheless offered little assistance exploring what’s in store.

A prescient dashboard gives better insight into conditions ahead and proactive systems for overseeing vitality explicit creation choices each moment of consistently. Envision taking all authentic vitality information – per item, per machine, per line, per office – and utilizing it to demonstrate future office practices.

Concluding Remarks

When it comes to energy efficiency for industry, there are a ton of ways that it could be achieved. With universal standard protocols in place, energy efficiency could be increased by leaps and bounds. On the other hand, this, in turn, could lower down the cost and shoot up the production volume astronomically.

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