5 Tips for Better Energy Efficiency in Industrial Operations

Businesses are constantly looking for ways to reduce operational costs while maintaining productivity. Sound familiar?

Well, it’s important to remember that energy efficiency goes beyond just being environmentally responsible. It’s also closely connected to protecting your bottom line and ensuring long-term sustainability. 

Whether you’re managing a manufacturing plant, chemical processing facility, or any industrial operation, implementing smart energy strategies can impact both your operational expenses and environmental footprint. 

Here are several proven strategies to help you maximize the “wins” in both categories simultaneously. 

• Optimize Your Compressed Air Systems

You might not realize it, but compressed air systems are often called the “fourth utility” in industrial settings, and they can account for up to 30 percent of your facility’s total energy consumption. Unfortunately, these systems are frequently the most inefficient part of an operation. These suggestions should help:

• Start by conducting a comprehensive audit of your compressed air system. Look for leaks, which can waste enormous amounts of energy – a single quarter-inch leak can cost you thousands of dollars annually. 
• Implement a regular maintenance schedule that includes leak detection and repair, proper filtration, and optimal pressure settings. 
• Consider upgrading to variable speed drive compressors that adjust their output based on demand rather than running at full capacity continuously.
• Don’t overlook the importance of right-sizing your system. Many facilities operate oversized compressors that consume excessive energy even during low-demand periods. By matching your compressor capacity to actual usage patterns, you can achieve significant energy savings.

• Implement Smart Motor Management

Electric motors drive the heart of your industrial operations, powering everything from conveyor belts to pumps and fans. Since motors typically consume 60-70 percent of industrial electricity, optimizing their performance offers major energy-saving opportunities.

One of the best things you can do is to replace older, standard-efficiency motors with high-efficiency or premium-efficiency models when they reach the end of their service life. While the upfront investment is higher, these motors can reduce energy consumption by two to eight percent, providing excellent return on investment over their lifespan.

You might also consider installing variable frequency drives (VFDs) on motors that don’t require constant speed operation. VFDs allow motors to adjust their speed based on load requirements, which can cut energy consumption by up to half in applications like fans and pumps. 

• Upgrade to On-Site Gas Generation Systems

If your operations require industrial gases like nitrogen, oxygen, or hydrogen, you’re likely spending significant money on delivered gas cylinders or bulk liquid deliveries. Switching to on-site gas generation can dramatically improve both your energy efficiency and cost structure.

PSA (Pressure Swing Adsorption) nitrogen generation systems are particularly effective for facilities that require high-purity nitrogen gas. These systems generate nitrogen by separating it from the oxygen in ordinary air through a cyclical adsorption process. PSA nitrogen generation systems offer a safe and reliable method for producing high-purity nitrogen gas on location for laboratories and various industries that require N2 in their applications.

The energy efficiency advantages are pretty compelling. Rather than the energy-intensive processes required to liquefy and transport nitrogen, PSA systems use ambient air and modest amounts of electricity to produce nitrogen on demand. This eliminates the energy waste associated with transportation, storage losses from boil-off, and the inefficiencies of over-ordering to maintain safety stock. 

As a cost-effective alternative to delivered gas, PSA systems typically pay for themselves within 12-24 months while providing greater supply security and reducing your carbon footprint. That’s some pretty decent ROI!

• Optimize Your HVAC Systems

Industrial HVAC systems are major energy consumers, but they’re often neglected in efficiency improvement efforts. You can achieve some decent savings by taking a more deliberate approach to HVAC optimization.

Proper insulation, weather sealing, and energy-efficient windows can dramatically reduce heating and cooling loads to start with. Then you can consider thermal curtains or doors for areas that experience frequent temperature changes, such as loading docks or areas adjacent to high-heat processes.

Another helpful upgrade involves implementing zone-based temperature control systems that allow you to heat or cool only the areas that need it, when they need it. Smart scheduling systems can automatically adjust temperatures based on occupancy patterns and production schedules. 

And don’t forget about waste heat recovery. Many industrial processes generate substantial heat that’s simply vented to the atmosphere. Heat exchangers and heat recovery ventilation systems can capture this waste heat and use it for space heating, process preheating, or other applications.

• Establish Energy Monitoring Systems

You can’t manage what you don’t measure. Implementing comprehensive energy monitoring systems gives you the visibility needed to identify inefficiencies and track improvement efforts. Modern energy management systems provide real-time data on energy consumption patterns, allowing you to identify peak usage periods, equipment malfunctions, and opportunities for load shifting.

Install submetering on major energy-consuming equipment and processes. This granular data helps you understand which operations are the biggest energy users and prioritize improvement efforts accordingly. Look for unexpected energy consumption patterns that might indicate equipment problems or operational inefficiencies.

Lastly, consider implementing automated energy management controls that can optimize equipment operation based on real-time conditions, energy costs, and production requirements. Some systems can automatically shed non-critical loads during peak demand periods or shift energy-intensive operations to off-peak hours when electricity rates are lower.

Adding it All Up

Industrial facilities aren’t exactly known for being the most energy efficient facilities in the world. However, that doesn’t mean there aren’t ways to improve in some key areas. By putting a focus on the strategies highlighted above, you can turn your facility into a much more efficient version of what it currently is. And that’s a win for everyone!