Download this checklist and use it to help implement quick wins that will help in reducing your energy usage and make your business more resource efficient. These measures can be easily implemented and have a significant impact on energy reduction, as well as having a cost-benefit.
You can edit the checklist to tailor it to your business requirements.
There are many ways to use heat in manufacturing processes, like drying, curing, sanitation, and more. By following these steps and making your heat use more efficient, you can save money and reduce emissions.
Check Your System
Older heat systems might not be very efficient. You can save money and reduce emissions by understanding how efficient your system is. Look at your fuel use compared to your system's rating and consider installing heat meters to track efficiency. When it's sensible, think about replacing old equipment with newer, more efficient models. It’s important to note that replacing equipment may be a longer-term, more expensive measure to implement.
Optimize scheduling
Take a look at your work schedules; can you operate your equipment for shorter, high-capacity periods? Small changes can yield significant efficiency gains. Aim for full loads when using dryers, ovens, and tanks as it's more energy efficient than doing multiple smaller loads.
Explore alternative methods: Sometimes, you can reduce the need for heat altogether. For example, consider mechanical de-watering techniques like pressing or centrifuging to minimize your reliance on heating.
Using waste heat
Don't let excess heat escape unused. Capture and repurpose it for various applications, from preheating materials to warming workshop spaces. This not only conserves energy but also trims costs.
Train Your Staff
Teach your staff about the right temperatures for processes. Sometimes, you can lower the heat and still get the same quality results. Also, make sure your staff knows how long it takes for equipment to heat up. This helps prevent unnecessary energy use.
Dyers play an important role in industries like chemicals and pharmaceuticals. Therefore, they likely account for a significant amount of your energy consumption. Here are some ways you can make them more efficient.
Manage moisture levels
Controlling moisture in your materials can reduce the need for extensive drying. Prevent excessive water from entering the feedstock during storage or consider product modifications to lower moisture content.
Regular Maintenance
Keep dryers in prime condition. Detect and address issues like damaged insulation, clogged air filters, air leaks, and product quality promptly to maintain efficiency.
Optimize Scheduling
Effective scheduling ensures equipment is preheated only when necessary. Identify areas where dryers run unnecessarily and consider automatic controls to manage heat-up times more effectively.
Ovens are often used in manufacturing for tasks such as baking and curing. These are some of the ways you can save energy used to run your ovens.
Inspect and Maintain Ovens
Regularly inspect your ovens for worn seals, damaged insulation, or inefficient operations. Prompt repairs prevent wasted heat energy.
Streamline Process Control
Determine the minimum heating time required and install automatic process controls to minimize heat-up periods, ensuring ovens are only heated as needed.
Preserve Heat
If you have batch ovens, ensure doors aren't left open longer than necessary. For continuous ovens, consider using air curtains to keep hot air inside, allowing staff to work close to open ends comfortably.
Tanks are often used in wet processes such as washing, glazing, heating caustic oil, and more.
Reducing Evaporation Losses
Heat often escapes from tank solutions due to surface evaporation. Reduce these losses by fitting tank lids and regulating solution agitation and extraction. This can slash heat loss by more than 50%.
Insulate Tanks
Cover tanks at night to curb heat loss and conserve energy. Proper insulation, with at least 50mm on sides and lids, can result in potential savings of up to 90% of heat energy.
Temperature and Heating Control
Avoid over-preheating and heating during idle tank periods. Regularly maintain and calibrate temperature sensors and controls to save energy and maintain product quality.
In manufacturing, compressed air is essential but can be a hidden source of energy waste, costing businesses unnecessary money. Reducing this waste can cut up to 30% of compressed air costs. The main areas of waste tend to be leaks in the distribution system, old, inefficient compressor equipment, and excessive use of compressed air by employees.
Turn it Off
If a compressor is not in use, make sure it's switched off, especially at the end of shifts or over weekends.
Cut Unnecessary Use
Identify where compressed air is used and ensure it's necessary. Sometimes, it's used just because it's available, not because it's the most efficient option. For instance, use low-pressure blowers for drying components instead of compressed air. When cleaning machinery, opt for brushes or vacuums if compressed air isn't necessary. Create a policy for when and where compressed air should be used and display it around the site.
Regular Maintenance
Follow the manufacturer's maintenance schedule, which includes lubrication, oil changes, and filter replacement. A well-maintained compressor can be 10% more efficient.
Detect and Fix Leaks
Industrial sites often have air leaks wasting up to 30% of energy. Implement regular leak-detection checks every three months. You can listen for leaks, use soapy solutions to spot bubbles, or use ultrasonic leak detectors. Once found, mark leaks on a system plan and repair them with proper depressurization and expert help for larger leaks.
Remove Unneeded Parts
Check for unnecessary components in the compressed air system, like unused pipework. Isolate unused areas to improve efficiency. If the system needs air at different times, use isolation valves to create zones.
Lower Air Pressure
Many systems use higher compressed air pressure than needed. Ask equipment manufacturers for the minimum required pressure and adjust the system accordingly. If one application needs higher pressure, consider a local generator rather than increasing the whole system's pressure.
Use Cooler Intake Air
Cooler intake air is denser, so the compressor doesn't have to work as hard. Bringing in cooler outside air can save energy. Measure the temperature difference to estimate potential savings.
Electric motors are widely used in manufacturing for various tasks, such as powering pumps, fans, conveyors, and more. They play a significant role in industrial processes and often consume a substantial amount of electricity. Inefficiencies in motor-driven systems can lead to unnecessary energy expenses. Therefore, improving the efficiency of your drives and motors can result in significant cost savings.
Optimization and efficiency upgrades
To reduce energy consumption and costs, manufacturers can consider the following:
Dyers play an important role in industries like chemicals and pharmaceuticals. Therefore, they likely account for a significant amount of your energy consumption. Here are some ways you can make them more efficient.
Manage moisture levels
Controlling moisture in your materials can reduce the need for extensive drying. Prevent excessive water from entering the feedstock during storage or consider product modifications to lower moisture content.
Regular Maintenance
Keep dryers in prime condition. Detect and address issues like damaged insulation, clogged air filters, air leaks, and product quality promptly to maintain efficiency.
Optimize Scheduling
Effective scheduling ensures equipment is preheated only when necessary. Identify areas where dryers run unnecessarily and consider automatic controls to manage heat-up times more effectively.
Ovens are often used in manufacturing for tasks such as baking and curing. These are some of the ways you can save energy used to run your ovens.
Inspect and Maintain Ovens
Regularly inspect your ovens for worn seals, damaged insulation, or inefficient operations. Prompt repairs prevent wasted heat energy.
Streamline Process Control
Determine the minimum heating time required and install automatic process controls to minimize heat-up periods, ensuring ovens are only heated as needed.
Preserve Heat
If you have batch ovens, ensure doors aren't left open longer than necessary. For continuous ovens, consider using air curtains to keep hot air inside, allowing staff to work close to open ends comfortably.
Tanks are often used in wet processes such as washing, glazing, heating caustic oil, and more.
Reducing Evaporation Losses
Heat often escapes from tank solutions due to surface evaporation. Reduce these losses by fitting tank lids and regulating solution agitation and extraction. This can slash heat loss by more than 50%.
Insulate Tanks
Cover tanks at night to curb heat loss and conserve energy. Proper insulation, with at least 50mm on sides and lids, can result in potential savings of up to 90% of heat energy.
Temperature and Heating Control
Avoid over-preheating and heating during idle tank periods. Regularly maintain and calibrate temperature sensors and controls to save energy and maintain product quality.
Download this action plan to track your progress against energy efficiency objectives.
