10 Tips on How to Reduce Energy Consumption in Manufacturing Sector

U.S. wholesale gas and electricity prices are rising with an 8 percent increase in 2022 from 2021 — that’s why reducing energy consumption in the manufacturing sector is essential

The Energy Information Administration (EIA) recently reported approximately 34 percent in the generation, transmission, and distribution losses. Furthermore, 66 percent of the original energy needed to generate power is lost when it reaches the customer’s meter.

On the other hand, EIA analysis highlights that there has been an increase in renewable generation capacity in the industrial, building, and electric power sectors compared to the reference case for Annual Energy Outlook (AEO) 2022. They also stated that it will help to expand the adoption of distributed generation in the building and industrial sectors and extend the availability of energy efficiency incentives through 2050.

The U.S. government and EIA are working hard to find energy-saving solutions because the power demand is reaching 4,027 billion kilowatt-hours (kWh) as 2022 comes to an end and will increase more in the upcoming years.

The breakdown of total energy consumption in the post-COVID19 era:

  • 1,477 billion kWh for residential consumers in the U.S.
  • 1,363 billion kWh for commercial customers in the U.S.

Companies looking to control energy wastage should make an appointment with APenergy’s energy efficiency consultants. Our team will provide advice and a valuable plan for saving and reducing energy consumption.

We inspect potential causes of high energy bills, such as leaky air compressors, inefficient equipment, and other energy hogs, through our energy reduction solutions.

This article covers how to reduce energy consumption in a factory and electricity consumption in an office.

Here are ten tips on reducing energy consumption in the manufacturing sector to control energy costs.

Create an Energy Management Team

First, build up a dedicated team responsible for energy management because this department will help save money.

An energy management team needs to have distinct roles and handle tasks, including:

  • Starting cost-saving initiatives or linking with energy efficiency consulting companies to streamline the energy management process
  • Tracking all the expenses and cutting them down by evaluating and synthesizing the received details from the representative of each area
  • Managing subject matter experts, like APenergy, to provide advice, industry experience, and “gap-filling” roles based on your existing assets to accomplish your energy goals.

Through continuous monitoring, a facility can reduce energy consumption.

Conduct an Energy Audit

Regular energy audits help management pinpoint the areas of a plant where energy is being wasted the most. Management can also utilize a manual on energy audits or receive help from facility professionals. Energy audits should be considered at both a high-level total energy review, and a systems review to make sure you are capturing all your opportunities available. It is important to remember that your total energy consumed is the sum of the parts, and most opportunities will be missed if you are just establishing high-level total energy reviews. It is one of the biggest oversights we see in the industry.

Energy audit reports can help management easily quantify or measure the following:

  • The amount of energy each department consumes
  • Identify the peak consumption times and which machines costumes the most energy
  • Clarify the required steps to reduce energy consumption without affecting manufacturing or production

Get Renewable Energy Systems

Renewable energy systems are becoming more frequently used because they produce little to no carbon emissions and are a free energy source.

Renewable energy systems include:

  • Wind energy
  • Solar energy
  • Biomass energy
  • Geothermal energy


The significant advantages are cost-savings and reduced demand on the utility company.

Today, many industrial and commercial firms are encountering difficulties in industrial energy management when acquiring an ideal renewable energy system – for more details, contact us at 740-862-4112.

Identify Energy Usage Peak

An energy audit shows a facility’s peak hours.

More is needed than an electricity bill when determining usage peaks. Automated meter reading equipment is the only way to determine when peak hours occur. With the help of these advanced meters, management can see energy usage in real-time. Management should also build energy efficiency methods to identify the downtime of energy usage during operating hours.

Still trying to figure out where to begin? Contact an energy savings consultant at APenergy. Our team provides ideal energy management and construction to reduce energy consumption.

Schedule Startup and Shutdown Periods

An energy audit will also determine the best times to use tools and machinery and help plan the production floor startup and shutdown schedule.

For shutdowns: management must decide what machinery needs to be powered off, such as during the weekend or off-shift periods — this enables management to reduce energy expenditures wisely.

For startups: management needs to determine what equipment can be left off during peak hours while relying on the latest machinery that aids energy conservation to maintain smooth production.

Maintain and Repair Equipment Regularly

Monitoring equipment and machinery daily will reduce energy wastage. Common causes for energy wastage include motors running hot because of poor https://apenergy.com/wp-admin/edit.php?post_type=custom-css-jslubrication, alignment concerns, and other issues. That’s why It’s crucial to have a proactive maintenance approach.

Installing condition-monitoring sensors is an excellent way to identify when a machine uses more energy than usual. The sensors also send a notification when maintenance is required.

Optimize Air Compressors

Industrial air compressors can cause significant energy waste and consumption due to poor design or inadequate maintenance. Management must take action to control the situation because it consumes a lot of energy, or contact APenergy to get a compressed air services & air system analysis.

The Compressed Air and Gas Institute reported that up to $3.2 billion in unnecessary energy costs are wasted yearly in the U.S. due to poorly maintained air compressors. Focusing on effective energy-saving methods to pinpoint leaks and improve compressors’ efficiency is vital to resolving wastage.

Quick tip: Schedule weekly maintenance for all central air conditioning systems.

Install Waste Heat Recovery Systems

Recycling waste heat helps to improve manufacturing energy efficiency.

The heat recovery process is helpful and can recover a lot of heat from the systems. It is also a practical technique to reduce pollution, which aids in environmental sustainability initiatives.

However, this type of cogeneration can be costly, so management needs to evaluate the size of the business to determine its worth.

Maintain Furnace Performance

Plants with furnaces should have regular maintenance to enhance performance and reduce wasted energy. It is also helpful to recover all the heat waste created by furnaces in the production process.

Essential tips for tracking accurate furnace performance and reducing the amount of overall energy usage:

  • Make sure that the stove is operating per a production schedule
  • Ensure all furnaces are functioning correctly to avoid unnecessary energy usage

Efficient Lighting Systems

The best way to instantly reduce energy is to use innovative and advanced products like a new lighting system.

Options for an efficient lighting system:

  • Electronic Ballast
  • LED Lights
  • Sensor Lighting Control Systems

Contact APenergy Today

APenergy has years of experience working with and helping clients navigate incentive programs through our incentive management service. We are dedicated to helping our clients achieve their renewable energy goals and are well-versed in facilitating solar project implementation.

Our expert team can help companies find the right incentives for their business under the new IRA of 2022 to reduce energy usage and carbon emissions for favorable ROIs. For more information, contact The APenergy team, the leading energy efficiency consultants, at 740-862-4112 or message us at (www.apenergy.com).