Energy saving guide for manufacturers

The Carbon Trust estimates that you could cut the energy bills in your manufacturing operations by as much as 20% just by implementing simple, inexpensive energy efficiency measures such as using variable-speed drives, fixing leaks in your compressed air systems, and cleaning your refrigeration condensers.

Here are some easy energy efficiency tips to get you started.

Motors

• Install variable-speed drives. These can reduce running costs when used for fans and pumps.
• Invest in high-efficiency motors. These might qualify for tax relief through the Enhanced Capital Allowance Scheme and could also help you to reduce your energy consumption.
• Maintain motor systems. Lubricate them where appropriate, and check belt tightness and alignment.

Compressed air

• Consider reducing the operating pressure of your compressed air. A 1-bar reduction could save about 7% of the energy required for compression.
• Switch compressors off when not in use. A compressor installation that is on when there is no demand will consume 20-70% of its full load power.

Refrigeration

• Check your door seals. A faulty one could increase the refrigeration unit's power consumption by as much as 11%.
• Avoid using too much refrigerant charge, as this can increase energy costs by over 10%.
• Clean refrigeration condensers. Dirty condensers can increase costs by around 26%.

Lighting

• Encourage staff to turn off lights when not in use.
• Label light switches so that it is easy to see which switch controls which light.
• Ensure that lights are switched off in unoccupied areas and when the premises are closed.
• Make the best use of natural light. For instance, ensure window blinds are open in daylight hours.
• Ensure security lighting time clocks change with the seasons. Fitting a daylight sensor control can also help.

Insulation

• Check the insulation on hot and cold pipework, and process ovens, for damage. Repair where necessary.
• Check whether valve flanges are insulated. If they are not, install jackets - payback periods can be as low as 12 months.
• Use lids on process tanks, especially out of hours, to prevent losses through surface evaporation.

Did you know?

• If you reduce a motor's speed by 20% with a variable speed drive, then its energy consumption could drop by as much as 50%.
• 12% of all the energy consumed by the manufacturing industry is used for heating buildings.
• Tuning your boiler could save over £800 per year.

Source: Carbon Trust