energy in manufacturing

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How to mount energy savings in high-volume manufacturing

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 [...]

How to prevent plant stoppage through energy management

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 [...]

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

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 [...]

Are energy meters like birdhouses or like screws?

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 [...]

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

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 [...]

3 lessons and 5 mistakes of IIoT projects

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 [...]

Use slow time to implement small improvements

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 [...]

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

#10. Energy audit saved $125,000 CAPEX

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

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

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. [...]

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 [...]