How Plant Operators Can Power Smarter Through Energy-Conservation

On the floor, behind the panels and running the machines, manufacturing plant operators aren’t just making things happen. They’re making it possible for businesses to move the world! Naturally, this requires a lot of power. At Flux Connectivity we know that manufacturing is heavy on energy. However, with a few clever moves, plant operators can make major dents in their utility bills. At the same time, they can boost their sustainability credibility.

Start with a reality check.

To start things off, it’s important to get a clear picture of where your energy is going. To do so, run an energy audit or walk-through your plant and list major energy users. Focus in on motors, compressed air, HVAC and lighting. It’s also wise to establish a baseline so you can track improvements. Getting this groundwork solid gives you the leverage to make smart, targeted changes.

Tackle the low-hanging fruit.

Let’s start with lighting upgrades, shall we? Replace your old lighting with LEDs and add occupancy or daylight sensors. Converting to LEDs and adding controls could produce major savings. Then, go ahead and switch off idling or unused equipment. You see, even when equipment is “standby”, it still uses power. The simple practice of powering down at end of your shift can add up.

Now it’s time for a little HVAC/insulation optimization. Be mindful that equipment leakages, poor insulation and inefficient systems drive large energy losses. Make sure ducts, pipes, walls and doors are tight and well-insulated. These steps don’t always require huge budgets, but they signal your energy-mindset and set the tone for deeper changes.

Process systems and controls.

If you’re ready to level up, focus on your big-ticket systems. We’re talking motors, compressed-air and process heating. Most plants spend more energy running motors for things like HVAC, pumps and compressors than any other system. Optimizing size, adding variable-speed drives (VSDs) and proper maintenance can reduce energy significantly.

Compressed air systems are notoriously inefficient. Leaks, poor layout and incorrect sizing all drive waste. Monitor and repair leaks, optimize system design and upgrade to energy-efficient compressors. As well, if you have heavy energy loads from induction heating and/or large presses, running them during off-peak hours or balancing loads can drop your energy costs.

Create an energy-aware culture.

All of the tech in the world won’t stick unless your team gets on board. Communicate the cost of energy and how each person’s action matters. Remind your team members to turn off machines and report leaks. Use data to back your requests. Show trends and celebrate your energy-savings wins. With people engaged, your energy-conservation efforts will become sustainable rather than one-off.

At Flux Connectivity we’re driven by one central purpose.

“Enable the acceleration of sustainable practices throughout our company and value chain by continually improving and promoting corporate responsibility.” This Sustainability Mission promotes a number of environmental objectives and practices.

We design physical goods with extended operational lifespans to reduce replacement frequency and waste. Obsolescence risk is evaluated during design and component-selection phases to support long-term serviceability and performance. Also, where feasible, we leverage shared infrastructure and flexible workspaces to minimize our carbon footprint associated with fixed facility usage.

To learn more, please don’t hesitate to give us a call at 1-800-557-FLUX or email us at connect@fluxconnectivity.com. You may also fill out the form on our Contact Us page!