In our microalgae-based wastewater treatment plant operations, we faced energy wastage due to human error, outdated machinery, and oversized equipment. Operators left systems running unnecessarily, and old pumps and paddle wheels consumed excessive power. To address this, we automated aeration and mixing, using variable speed drives to adjust in real-time. We installed solar panels, switched to low-voltage LED lighting, and implemented biogas recovery from waste. Replacing oversized pumps with right-sized models further cut energy use, improving efficiency and reducing costs.

Hay mucho potencial de optimizar en plantas industriales (más aún en eficiencia energética). Lo hago de esta manera: ? Realizó una auditoría energética para detectar áreas de pérdida de energía. ? Identifico equipos obsoletos y optimizo su rendimiento. ? Capacito al personal sobre el uso eficiente de energía en operaciones diarias. ? Reviso el aislamiento térmico para minimizar pérdidas de calor.

6. Explore opportunities to implement projects related to Waste Heat or Energy recovery. 7. Keep all these previous steps as a continuous improvement system.

We need to understand the production cycle per product, teatime (15 min every 2 hrs) and lunch time (1 hr), only then we can implement automation in our utility machines. We need to understand machine circuits and production cycle thoroughly then we can implement energy saving concept. Before implementing anything in machine you need discuss with the concern department manager and bring everything in paper how and how much energy can be saved. Prepare checklist before implementing energy saving concept in plant machine. In my last company I had a lot of energy savings in Kaizen, where one Kaizen was by shutting down the chiller and providing cooling tower water to cool the double disc grinder machine. It has been successfully implemented.