How much money is at your ‘energy waste’ account?
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 decisions here. Me: You just [...]
#8. Energy audit busts ‘Nothing to save, Everything is automated’ belief
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 'ON' fume hoods at night [...]
Energy waste is invisible, until you measure it
A prospect informed about a possible massive cost of compressed air leaks responded: “What leaks? I do not hear hissing noise from compressed air leaks on the floor.” Plant manufactures gravel. Production noise is deafening. To hear compressed air leak would be a disaster, not only for energy bill, but likely for the whole production process. If leaks are [...]
#7. 4 sources of energy waste at plants with efficient machines
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 lighting/cooling/heating/ventilation Inadequate controls: broken, temporarily [...]
#6. 6 beliefs about energy efficiency busted by energy audits
We often hear: "Our plant runs at top energy efficiency because we use these procedures and settings and our efficient equipment is fully operational." Just how often is this true? With all due respect to maintenance and operational staff, recommendations of a proper energy audit are based on direct observation of operations and lots of measurements. Routinely results of [...]
#5. How to reduce energy cost when CAPEX is limited
A lot of energy costs can be saved at manufacturing plant without CAPEX.
#4. Energy savings at manufacturing plant beyond LED, VFD and idling
Complex energy audit does not look at energy alone. It considers how energy use affects core business - production, quality, scrap, employee productivity.