Manufacturers have already taken several actions to reduce their energy use. The most common include:
- replacing existing lighting with motion-controlled LED systems
- adding insulating jackets to machines
- procuring electricity from renewable energy providers
- insulating buildings
- replacing old equipment such as motors and drives with modern, more efficient versions
- reinforcing the need to turn off equipment and systems when not in use
Businesses are now considering more sophisticated and creative solutions, yet many don’t where to start. A recent Discussion Group chaired by Jonny Williamson explored how Made Members are looking to take their energy efficiency programmes to the next level.
The roundtable-like conversation followed an informative presentation from Richard Kenyon, Operations Director at Leicester-based COBA Automotive. Richard outlined his organisation’s energy efficiency journey over the past five years.
At the start of that journey, the team investigated the business case for a solar panel installation but concluded that the technology wasn’t the right fit. One reason was the projected 10-year return on investment (based on the cost of electricity at that time).
That changed in 2021 when the team realised the business would see an increase in energy cost from £62,000 a month to £138,000 once its fixed deal ended. As a result, COBA now has an installation of 1,000 solar panels and eight 50kW inverters that will deliver an ROI in 3.5 years.
Richard’s case study highlighted the importance of revisiting technologies and appraising them in the current context. Landscapes can change dramatically over time, particularly in a market as volatile as energy, so what was unattractive several years ago could now be a viable solution.
All those in the Discussion Group agreed that energy efficiency and a broader sustainability strategy had moved from nice to have to business imperative. Though surprisingly not every organisation has undertaken a in-depth energy audit.
With manufacturers unsure how to lower their utility costs, these surveys provide a clear overview of current energy usage and valuable insights into areas that could be improved.
An often-overlooked problem highlighted through such audits are leaks in compressed air systems. These leaks can be a significant source of wasted energy, representing as much as 30% of a compressor’s output. It’s estimated that a leak of just 1mm can cost a factory upwards of £1,500 a year.
The group went on to discuss the pros and cons of installing a voltage optimiser (VO). These transformer-based devices essentially work like a valve and step down the power supplied from the National Grid, usually between 230V and 240V, to the 220V most appliances require.
An industrial VO typically costs between £25,000 and £30,000 and can reduce energy consumption by between 5% and 15%, depending on site-specific requirements.
It was noted, however, that optimisers will provide little to no savings for devices that rely on thermostats, such as ovens, heaters, and refrigerators, and LED Lights. The best use cases are motors and incandescent lighting. Harmonics (distortions in the electrical power system) are also a potential issue with VOs, particularly when used to power sensitive electrical equipment.
The discussion concluded by stressing the importance of education:
- for employees – i.e. turn equipment off when not in use / at the end of the day
- for employers – i.e. understand what solutions are available and where they can best perform (or not!)
- for policymakers – i.e. recognise that an energy-intensive manufacturing business has different needs to a typical commercial enterprise
The final word went to an attendee who noted that reducing energy consumption was good but eliminating it was even better. An automatic part of how many people start work is to turn on every machine in their workspace. His organisation has a philosophy based on using energy for a purpose, “There has to be a reason for switching on a machine; if there isn’t, we don’t,” he explained.
Meet, confer and share best practice
Opportunities to openly discuss and consider challenges, opportunities and solutions are why the Made in Group’s Virtual Breakfast Mornings are so invaluable.
80 minutes out of your morning to hear inspiring and thought-provoking conversations, build relationships with like-minded fellow manufacturers, and gain a clearer picture of what’s happening beyond your factory gates.
We look forward to seeing you at the next one:
*Header image courtesy of Pixabay