Industrial and manufacturing facilities use a lot of energy – in fact, in 2022, the industrial sector accounted for one-third of total U.S. energy consumption! Because of their unique energy demands (heavy machinery, climate control for large spaces, production-specific processes, etc.), finding efficiencies wherever possible is crucial. Let’s explore some energy-efficient tips for industrial and manufacturing facilities.
Conduct Audits
The average manufacturing facility in the U.S. is around 16,000 square feet. That’s thousands of square feet filled with lighting, equipment, appliances, HVAC, etc., affecting your energy bill. And with such a large space, it’s hard to pinpoint when one thing isn’t performing efficiently. An energy assessment can help.
- Collect data: Gather current and past energy bills, record energy usage and maintenance schedules, do a facility walkthrough, check for leaks, and observe how your team uses machinery. Use this checklist as a guide.
- Analyze: Once you’ve collected your data, go through it with a fine-tooth comb. Are there energy spikes from one bill to the next? Has all equipment received timely maintenance? Is machinery being left on unnecessarily?
- Recommend changes: Your post-analysis findings should reveal some clear improvements. Compile them.
- Take action: Turn your recommendations into a to-do list. Outline a plan for yourself and your team and inform them of any daily changes they need to implement.
Improve Equipment Efficiency
When working with hundreds or even thousands of machines, energy use adds up quickly. Consider replacing outdated machinery with energy-efficient alternatives designed for industrial use.
If you can’t replace machinery, consider replacing any V-belts with cogged or synchronous (notched) belts. According to the U.S. Department of Energy, notched belts run cooler, last longer, and are more efficient than standard V-belts.
Another energy-efficient tip for industrial and manufacturing facilities is to install variable speed drives (VSDs). VSDs control motor speed and torque. They offer many benefits, including precise process control, extended equipment lifespan, reduced operational costs and environmental impact, and improved overall productivity.
Control the Climate
In commercial buildings, heating, cooling, and ventilation account for nearly half of the energy used on-site. So, when you oversee something as large as an industrial or manufacturing facility, temperature control is vital.
- Divide the facility into zones to optimize heating or cooling based on each area’s specific needs.
- Use high-quality air filters to collect pollutants and allergens (and replace them regularly). This will improve HVAC efficiency as well as indoor air quality.
- Install smart programmable thermostats so temperatures can easily be adjusted based on time or occupancy.
- Utilize industrial ceiling fans to distribute air evenly and help reduce heating and cooling costs.
- If possible, capture wasted heat expelled from equipment and redirect it for facility heating.
- Use dehumidifiers to manage moisture levels and help reduce cooling costs. This helps maintain the quality of your products, too!
Optimize Lighting Systems
Did you know lighting accounts for 17% of all electricity consumed by American commercial buildings? The larger your manufacturing facility, the easier it is to rake in energy savings.
Start by installing LEDs. LEDs are just as bright as traditional incandescent bulbs, but they use 90% less energy and last 15 times longer! Plus, they omit very little heat (compared to traditional bulbs, which release 90% of their energy as heat), so they can help you save on your cooling costs, too.
Next, lighting can be automated by installing occupancy sensors. This will help reduce wasted energy in less frequently used areas, like break rooms or storage closets. You can even set these sensors to dim when there’s more natural light.
Become an ENERGY STAR Partner
Over 800 manufacturing companies across the country partner with ENERGY STAR. There are many benefits of an ENERGY STAR industrial partnership:
- Strengthen your energy program through coaching and mentoring.
- Learn from leading energy managers and their programs.
- Gain a strong network of industrial energy managers.
- Learn industry best practices.
- There are no fees, legal commitments, or reporting requirements.
ENERGY STAR also has an Industrial Assistance Network that helps small and medium-sized manufacturers access local energy management support through training opportunities, tools, networking, and coaching. The U.S. is divided into 10 regions, so you can join the leading energy-efficient manufacturers in your area.
Work with Energy Experts
As part of UGI Corporation, we are backed by 140 years of expertise in energy, complemented by an expanding energy infrastructure. At UGI EnergyLink, we’re here to support all your manufacturing and industrial facility energy needs and will provide a customized plan that works just for you.
Let’s talk – request a custom energy quote today!
Want to learn more energy-efficient tips for industrial and manufacturing facilities? Download our Business Owner’s Energy Guide!