Running a manufacturing plant of any sort is a complex responsibility that requires you to think about a number of factors ranging from efficiency and safety to productivity and profitability. And it’s at that intersection of each of these factors that you’ll find the issue of energy costs.

As a plant manager or business owner, reducing energy costs is central to your larger goals. But, unfortunately, it’s not always easy to know where to start.

With this in mind, we’re going to discuss five ways you can reduce energy costs in your manufacturing plant or growth and improvement across the board.

 

1. Upgrade to Energy-Efficient Equipment

One of the best ways to reduce energy costs is to upgrade your equipment to more energy-efficient models. This includes everything from large machinery to smaller devices, as well as lighting and HVAC systems.

When shopping for new equipment, look for the Energy Star label or other certifications that indicate energy efficiency. You want to purchase from brands that are meeting independent certifications and not just making clever marketing statements.

Although these upgrades might involve a significant initial investment, the long-term savings are substantial. Over time, you’ll notice a decrease in your energy bills, which will offset the initial costs of the equipment. Additionally, energy-efficient equipment often comes with the benefit of being more reliable and having a longer lifespan, further enhancing your return on investment.

Another option is to add new equipment and technology when it’s shown to proactively address energy efficiency issues with existing equipment. For example, many manufacturing plants benefit from having air-cooled chillers, which can save as much as 5 to 15 percent of energy by pulling heat from the environment into the chiller and cooling it down.

 

2. Implement a Regular Maintenance Schedule

Regular maintenance of your equipment is essential for ensuring it operates at peak efficiency. Machines that are not well-maintained often consume more energy because they have to work harder to perform their tasks. Simple maintenance tasks, such as cleaning, lubricating moving parts, and replacing worn-out components, can keep your equipment in tip-top shape and significantly reduce energy consumption.

Create a maintenance schedule that includes regular inspections and servicing of all equipment. This helps in reducing energy costs, as well preventing unexpected breakdowns that can disrupt your production process. Maintenance should also extend to your HVAC systems and lighting fixtures. For example, replacing old light bulbs with LED lights can drastically cut down on energy usage while providing better illumination. (LED bulbs use up to 90 percent less energy and can last 25-times longer than regular incandescent bulbs.)

 

3. Optimize Your Production Processes

Evaluate and optimize your production processes to create even more significant energy savings. You’ll want to begin by conducting an energy audit to identify areas where energy is being wasted. This can reveal inefficiencies in your production line, such as machines that are left running when not in use or processes that could be streamlined to reduce energy consumption.

Once you have identified these inefficiencies, work on making your production processes more energy-efficient. This might involve reorganizing your workflow and reducing idle times. Or it could look like making sure your machines operate at their optimal settings. (For example, staggering the start-up times of large machinery can prevent energy spikes and reduce overall consumption.)

 

4. Use Energy Management Systems

Investing in an energy management system (EMS) can give you real-time insights into your energy usage and help you control it more effectively. An EMS allows you to monitor energy consumption across different areas of your plant and identify patterns that can be addressed to save energy.

With an EMS, you can automate the control of lighting, heating, and cooling systems based on occupancy and production schedules. For example, lights and HVAC systems can be set to operate only when needed, reducing unnecessary energy use. These systems are also able to alert you to any irregularities in energy consumption. (Having this level of visibility is invaluable.)

In addition to monitoring and control, many EMS solutions offer analytical tools that help you understand your energy usage in greater detail. You can then turn around and leverage this data to make informed decisions about where to invest in energy-saving measures.

 

5. Train Your Employees

Your employees play a critically important role in managing and reducing energy consumption. By training them on energy-saving practices and encouraging a culture of energy efficiency, you can achieve significant reductions in energy costs. Start by educating your staff on the importance of energy conservation and the impact it has on both the environment and the company’s bottom line.

 

Implement training programs that teach employees simple actions they can take to save energy. This might include turning off machines and lights when not in use and utilizing natural light when possible. It’s a good idea to proactively encourage employees to be mindful of energy use in their daily tasks and recognize those who make notable contributions to energy-saving efforts. (You don’t have to offer financial rewards. Sometimes verbal affirmation is the best incentive you can give.)

 

Adding it All Up

If you want to get serious about reducing energy costs in your manufacturing plant, you can’t sit back and hope or wish it happens. You need to get practical and proactive. The five strategies highlighted in this article will provide you with an excellent place to start. Begin with one of the ideas and then move on to another. Baby steps can produce big results!

Article by Community Writer.