energy in manufacturing

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 [...]

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 [...]

19 05, 2020

Are energy meters like birdhouses or like screws?

By |2020-06-03T10:33:14-04:00May 19th, 2020|Categories: Energy management, Energy management education|Tags: , , , |0 Comments

It occurred to me that meters relate to energy monitoring in the same way as screws relate to birdhouses. How is that? Some manufacturing plants start energy management from installation of meters. Too often the process ends with meters too. However costly, this result is predictable. I will explain why on an example of [...]

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 [...]

22 04, 2020

3 lessons and 5 mistakes of IIoT projects

By |2021-02-10T15:58:57-04:00April 22nd, 2020|Categories: Energy management, Energy management education|Tags: , , , |0 Comments

Sam Hoff, president of Patti Engineering. suggests to start collecting data only after one has identified the problem. See IIoT project success: First identify the problem, then begin collecting data. I think he meant to say "problem area", because if you know what the problem is - you do not need more data, you need [...]

16 04, 2020

Use slow time to implement small improvements

By |2020-06-03T10:33:15-04:00April 16th, 2020|Categories: Energy management|Tags: |0 Comments

Slow production time is an opportunity to do that myriad of small projects that maintenance kept suggesting for years, but could never implement because 'production comes first'. Now is the time to do them. How to find micro maintenance/efficiency projects during slow time? When external resources are limited, what do we do? We turn [...]

23 03, 2020

#10. Energy audit saved $125,000 CAPEX

By |2020-06-03T10:33:15-04:00March 23rd, 2020|Categories: Uncategorized|Tags: , , , , , |0 Comments

Reduction of air exhaust from refrigerated room reduced cooling load and eliminated need for refrigeration plant upgrade

16 03, 2020

#9. Energy audit finds $20,000 in energy savings at a cost of a 30 ft pipe.

By |2020-06-03T10:33:15-04:00March 16th, 2020|Categories: Energy management, Energy management education|Tags: , , , , , , |0 Comments

A perfectly efficient machines can still waste lots of primary or secondary utilities. A complex utility audit routinely uncovers how water, heat or 'cooling' can be reused. Hot water reuse at poultry slaughter house Two industrial poultry processing procedures were set in adjacent production space - vacuum pump and scalding. [...]

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