industrial energy management

29 03, 2022

Utility waste at manufacturing plant is a choice, money is not the issue

By |2022-03-29T11:31:32-04:00March 29th, 2022|Categories: Business value, Energy management|Tags: , , , , , |0 Comments

I often hear that "Energy audit costs money, but saves no energy". This is true and not true at the same time. Here is why: Any experienced plant manager knows that their plant wastes utilities. No shame in this. Every plant wastes energy. Few plant managers know where exactly this waste occurs and even [...]

20 01, 2021

How to mount energy savings in high-volume manufacturing

By |2021-01-14T17:42:47-04:00January 20th, 2021|Categories: Energy management, Energy management education|Tags: , , , , |0 Comments

Our South African colleague Craig van Wyk from VWG Consulting expressed a consideration very much worth republishing: if savings per unit are achieved and sustained in high-volume manufacturing, they keep mounting every hour of every day. Here is Craig's message: During my years in management in the high-volume manufacturing environment, prior to becoming a [...]

21 12, 2020

How to prevent plant stoppage through energy management

By |2020-12-18T14:53:11-04:00December 21st, 2020|Categories: Business value, Energy management, Production level, Profitability|Tags: , , |0 Comments

A mere 1 month after an Energy Management Information System (EMIS) project was postponed ‘due to other priorities’ our client’s plant has stopped for 3 days. About $500,000 lost in pre-holidays food product sales. Not to count costs of avoidable urgent repairs and value of lost trust from clients. Why did plant stop? Boiler [...]

16 11, 2020

To be approved an energy project must start with business goals, not with engineering tools

By |2021-07-14T17:54:08-04:00November 16th, 2020|Categories: Energy Efficiency Tips, Energy management|Tags: , , , |0 Comments

To be effective energy management project must start with goals to be achieved, not tools and technologies available. Managing energy has no meaning if it does not contribute to what your plant is doing. However profitable a project is, if it does not contribute to production, quality or safety, it will always be assessed [...]

5 10, 2020

Use of average energy intensity can hide savings or show fake savings

By |2020-10-01T18:19:05-04:00October 5th, 2020|Categories: Energy management, Energy management education|Tags: , , |0 Comments

A common way to determine energy intensity in manufacturing is to divide energy cost by production volume, resulting in kWh per car or m3 per pound of bread. This simplistic approach may hit energy manager where it hurts the most - at evaluation of completed projects. A good well-implemented project may show dismal savings [...]

27 04, 2020

#11. How to estimate possible energy savings in 25 minutes and at no cost?

By |2021-02-10T15:58:38-04:00April 27th, 2020|Categories: Energy management, Energy management education|Tags: , , , , |0 Comments

Energy audit takes time and costs money, is it worth the effort?  How do I know if it will uncover enough saving opportunities? To quickly estimate how much money can be saved on utilities, we have devised an express tool - Energy Management Score assessment™. EMS is based on a premise that the way [...]

14 04, 2020

Simple energy management procedure cuts energy costs during uncertain times

By |2020-06-03T10:33:15-04:00April 14th, 2020|Categories: Energy management|Tags: , , |0 Comments

During quarantine time many plants face uncertain work load and even less certain revenue. The simplest way to save energy and cost to turn unnecessary machines off. This simple recommendation is rarely easy to implement, it's even more difficult to monitor. How to find if unneeded machines are turned off without breaking a bank? [...]

11 03, 2020

How much money is at your ‘energy waste’ account?

By |2020-06-03T10:33:15-04:00March 11th, 2020|Categories: Energy Efficiency Tips, Energy management, Energy management education|Tags: , , , |0 Comments

Situation Doing nothing is an investment decision too. Investment with a guaranteed return of nothing. Here is a common conversation at a manufacturing plant: Me: … Implementation will cost you $5K and save $15K within 12 months. Maintenance manager: So we save $10K?  Not much for our plant. Besides, I do not make investment [...]

9 03, 2020

#8. Energy audit busts ‘Nothing to save, Everything is automated’ belief

By |2020-06-03T10:33:15-04:00March 9th, 2020|Categories: Energy management, Energy management education|Tags: , , , , , |0 Comments

A common objection to doing an energy audit is that 'Everything is fine'. This is rarely the case. Here are two examples when audit uncovered saving opportunities that clients did not know existed because they believed everything was in perfect state already. Efficient equipment does not equate to efficient operation. Sanitation staff turned [...]

2 03, 2020

#7. 4 sources of energy waste at plants with efficient machines

By |2020-06-11T11:53:09-04:00March 2nd, 2020|Categories: Energy management, Energy management education|Tags: , , , , , |0 Comments

A common belief is that if plant is equipped with efficient machines it runs efficiently. Unfortunately, this is not always true. Efficiency of components does not equate to efficiency of the whole plant. Common reason for utility waste by efficient machines: Misuse: compressed air used instead of blowers or for cooling, oversized motors, excessive [...]

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