How can manufacturers improve their energy efficiency?

Carrying out audits is the first step, since many times we do not have an appropriate baseline, however it is necessary to continue measuring the energy and hydraulic flows since their optimization goes hand in hand, knowing both the averages and peaks of use. - benchmark consumption per productive unit - Areas of greatest use - Digital technologies and trend analysis are crucial - Monitoring improvement implementations and their performance

In process industries the base case energy needs are largely defined by the design parameters . An internal audit can point out those unit operations which are operating with higher than design energy requirement and need to be looked into . One may then establish its root cause followed by correcting the operations parameters to get close to the design data.

To improve energy efficiency, one should follow the step by step analysis approach 1. Capture the data of existing energy consumption. this can be achieved with the help of state of art BMS/FMS tools with real time data capturing 2. get the energy audit done with the help of captured data. 3. look for the avenues of reduction of the energy consumed. use of sensors and automated systems to control is the key. 4. Look for approaches to shift your energy consumption to renewable energy sources. 5. increase awareness within the steak-holders and employees about energy efficiency. 6. Incentivise the new ideas of energy saving and initiatives.

You should appoint a champion of energy savings which will lead the organisation in the energy master plan. About the plan you could use the already systems made as an example ENERGY STAR in USA.

If you can't measure it, you can't improve it! The standard procedure for continous improvement is: (i) Measure it. (ii) Record the measurements. (iii) Analyse the recordings. (iv) Act on the analysis. Of course, the key element in all this is teamwork/people. When acting on the analysis, One should set very bold targets for the improvements.

Ideas to Implement Energy Management Systems (EMS): 1. Start Smart: Audit and Analyze: understand your current consumption patterns Set Measurable Goals: Define and quantifiable energy efficiency 2. Leverage Technology: Invest in Smart Systems to collect real-time data on energy used. 3. Empower your People:Engage Stakeholders: Build awareness and educate employees, about energy efficiency. 4. Optimize Operations: Implement Efficiency Measures: Upgrade outdated equipment with energy-efficient models to minimize carbon footprint. 5. Continuous Improvement: Monitor and Evaluate Foster Innovation: Encourage a culture of continuous improvement, successful EMS implementation is a journey, not a destination.Consider the financial feasibility

Your comprehensive explanation effectively highlights the key aspects of an Energy Management System (EMS), emphasizing its role in enhancing energy efficiency, regulatory compliance, and operational efficiency. The mention of ISO 50001 adds credibility, showcasing a recognized standard for effective energy management practices. Overall, a well-articulated overview of the importance and benefits of implementing an EMS.

Implementing an Energy Management System (EMS) involves: 1. Defining objectives and scope 2. Conducting an energy audit 3. Selecting suitable software 4. Installing meters and sensors 5. Configuring and integrating the system 6. Training personnel 7. Regular monitoring and adjustment Benefits of EMS include: - 10-30% reduced energy consumption - 10-20% cost savings - Improved efficiency and sustainability Consider certifications like ISO 50001 and LEED, and popular solutions like Siemens Desigo and Schneider Electric EcoStruxure. By implementing an EMS, organizations can optimize energy usage, reduce costs, and enhance sustainability.

Implementar sistemas de gest?o de energia n?o é apenas uma resposta aos desafios contemporaneos, mas uma oportunidade para as organiza??es liderarem a revolu??o rumo à sustentabilidade. Ao adotar uma abordagem proativa, as empresas n?o apenas maximizam a eficiência, mas também moldam um futuro onde a gest?o de energia é sin?nimo de inova??o e responsabilidade. #Gest?oDeEnergia #SustentabilidadeEmpresarial #EficiênciaOperacional"

In the context of this article, each aspect is crucial and interrelated. However, a well-designed Environmental Management System (EMS) assumes a pivotal role in monitoring and sustaining improvement. While the influence of more affordable technologies has been radical, engaging in this field requires a systematic approach for analysis and identification of improvement points.

In addition to upgrading equipment, fostering an energy-efficient workplace involves cultivating a culture of awareness and responsibility among employees. Implementing training programs and promoting energy-conscious behaviors can lead to sustainable practices. Employee engagement, coupled with technological upgrades, creates a holistic approach that not only enhances energy efficiency but also builds a sense of shared responsibility toward environmental sustainability within the organization.

Some basic points to be consider 1. Get the complete audit of your equipment through OEM. 2. Analysis the report and discuss with OEM for suitable retrofit. 3. Evaluate the cost of retrofit and determine the return on investment. 4. Evaluate the downtime for retrofit to ensure minimum stoppage to your business operation 5. Ensure post retrofit service support.

We use since years the perspective of energy balancing. In one room dryers generate excess heat energy, which is then exchanged to chilling energy transferred to the room besides for a controlled cooling process. In a large and high machinery hall we have large heat exchangers under the ceiling and transfer this energy back for heating and lighting people’s workplaces. A third installation in a hall with 3 furnaces, where we see an important air cooling effect from excess heat being transferred via pipes to neighboring halls and Admin building heatings. This principle similar to our homes, where outside air is de-energized in order to heat floor and water systems and chilled air is exhausted.

In my experience upgrading to newer technology is the best way improve energy efficiency. This also is the stepping stone for implementing better controls with tighter spec requirements to increase and track quality.

Technology shift is a must when you want a quantum change. But only technology will not help. Mindset shift is equally important and hence we need to invest equally on our workforce to make them capable to sustain the quantum of change brought into the system

Agreed… Process Optimisation can improve productivity at low cost. Through process optimisation, at #WesCEF, we have increased production of Nitric acid, ammonium Nitrate, Sodoum Cyanide and ammonia plants. Advanced process control system played a key role into this optimisation journey. Incremental increase in production with lean process management has improved specific energy/raw material consumption resulting in reduction in CO2e- emissions intensity.

In the plants I've been through, I see three things that are overlooked which are simple fixes that yield good results with regards to energy efficiency. 1. Poorly maintained steam traps constantly blowing steam. 2. Compressed air leaks, especially when involving instrumentation. 3. Water hoses left running. Fix these things and avoid "death by 1000 cuts". They are simple and require no capital.

One thing I found interesting is that advanced process control (APC) solutions (fuzzy logic, neural networks, model-based predictive control, etc.) help the process remain very close to the optimum level of operation leading to a stable process and reduced specific energy compared to manual operation. Some years ago, the APC deployed autonomously discovered an astonishingly new low in the separator fan speed in a cement plant in western India leading to energy saving.

Through the first law of thermodynamics, we understand energy can’t be created nor destroyed. If you consider this in thermal systems, most of the primary energy isn’t being used but rather wasted through vents or down the drain. In light industry, this can be 70% of the energy! Doing thermal mapping and pinch studies can help find waste heat sources and heat sinks in a facility. Knowing this can help you identify where direct heat recovery can be used. Once that’s done low-grade heat recovery with a heat pump can be used to further optimize your system. This Circular Thermal methodology is the best way to truly optimize your thermal systems.

I'm not sure if this fits in here or a different category but you can run VFD on most motors to optimize energy usage, you can look at the needs of your facility and make sure pumps and motors are sized right for your current needs and not your old needs. I think we update the processes but not the equipment that goes along with it.

The working culture has to be in such a manner that achieving best energy efficiency is a mirage! As you implement improvements, the goal post also keeps on raising! This has to be viewed as a challenge by the team.

Praise the team and hold regular topic meetings where the team focuses on the goal in a friendly atmosphere. Keep away managers who don't feel like sponsors or contributors. Always work with the team to maintain the measures that are easy to solve. Give the team success on how to improve the current situation and they will run like crazy to achieve more. Make communication and recognition, best practice and challenge your DMS KPI to the new level.

Energy needs to be part of the winning proposition for any facility. Typically there is an integrated set of goals for any facility. It can be ESG, production, expense and margin management to name a few. As a result functional excellence in energy needs to be woven into the goals for the organization so that the organization comprehends the mission.

People and Processes are the key to any business and the biggest differentiator for an organization. Effective communication and involving people in the organizational goal is equally important for a major breakthrough and sustainable development of any business. As per my experience, half the business / work is done when the purpose, the approach and the final expectations from the role is effectively shared / conveyed by the leader / supervisor. Without awareness and achievement will always remain handicapped !

In my experience, engaging the Team on the floor is probably one of the best methods to improve. The boots on the ground need to be empowered and rewarded, this will often cause Teams to be more personally invested in the success of the overall operation. I have found my best eyes and ears are those actually utilizing the systems, these individuals will let us know the moment somethings gets out of whack. Company Culture today is focused on profit only, in most cases. Leaving out the people on the ground will eventually cause the system to fall apart. We all have been plants that are in terrible shape and no one seems to care. That's a business on the brink of death.

Energy efficiency is?the use of less energy to perform the same produce the same result. Energy-efficient use save our planet from global warming.

The energy efficiency can be effectively measured through reduction of energy cost per product. In my experience, develop an energy auditor internally to monitor and track the consumption. Assess current condition. Implement additional controls and kaizen to save energy. Put the best practices of " switching off" when not in use. Implement Energy audit mechanism in each of your floor to ensure. Additionally see the improvement items while your audit. Seek management support in addressing those audit findings , ask resource in terms of Budget. Example replace existing lights to LED & solar energy usage maximization. The energy audit team has to be empowered to make proposals to fix energy wastage issue. Then make shop manager Accountable

In my experience, engaging manufacturing employees is the key to improve efficiency and energy usage. 1. Brand name the program and kick it off to the full team with the top leader speaking. Feel free to be clever on the program name or hold a naming contest. 2. Hold brainstorming sessions and create “suggestions boxes.” 3. Create awareness about the types of waste such as, Overproduction, Inventory, Defects, Motion, Over-processing, Waiting and Transportation 4. Incentivize participation by offering a percentage of what is saved or gamifying for a department pizza party, etc. 5. Track, measure and put guards in place to sustain the gains, and don’t forget to 6. Celebrate the Wins! Thanks for asking, Coach Jen

Operations concentrating on the availability of compressed air volume and pressure but the least concerned about the air leaks is observed very often. The amount of energy that can be saved by arresting those leaks is huge

Consider refurbishment and overhauling of all old electric motors to modern AC and four quadrants speed drives. Together with up to date reactive power compensation equipment, most of times it's a quick win investment.