Energy is a necessary component for all types of ventures. Industrial processing and manufacturing facilities are often the primary users, but even service businesses like insurance and banking need vast buildings that need heating, cooling, and lighting. Data centers, the latest major energy-intensive establishments, consist of extensive clusters of computers that store and distribute the data sent over the Internet. Irrespective of the intended purpose or the sector, almost all entities aim to reduce production costs by decreasing energy use. And, this is the reason, energy management in manufacturing is very important.
Apart from economic incentives, there is a growing consensus that each unit of energy produced by burning fossil fuels (which accounts for the bulk of our energy) results in a rise in atmospheric carbon dioxide levels. Consequently, these shifts seem to be leading to unfavorable alterations in the Earth’s overall climate. There are increasing numbers of incentives to prioritize energy management in the industrial sector.
Energy Management in Manufacturing
To achieve a significant decrease in total energy use, it is necessary to engage in careful strategizing and get a commitment from all levels of the organization. For instance, let’s take a product that undergoes the following steps:
It is dried using a dryer powered by natural gas, then cured, further dried to achieve the desired dryness using an electric dryer, and lastly coated. If management were to respond to a “directive to conserve energy,” they may perhaps decrease the quantity of gas used in the first dryer.
However, this activity might disrupt the curing process and result in higher energy consumption in the electric dryer, which is more costly to operate compared to the gas dryer. Engaging in this single activity would ultimately lead to an increase in overall energy consumption and manufacturing expenses, perhaps causing issues with product quality. Energy management in manufacturing industries may prevent such errors from occurring. The objective of this regimen is to systematically decrease energy consumption inside a company, and it has two crucial elements.
Collection & Analysis of Energy Data – Crucial Element of Energy Management in Manufacturing
The fundamental component of an energy management program is the collection and examination of energy data. It is crucial to be able to evaluate the present levels of energy use and assess potential enhancements. Industrial energy management software must have the capability to:
- Acquire data from diverse sources such as discrete meters, DCSs, PLCs, databases, and other data-gathering systems
- Aggregate data from several plant locations, if necessary
- Archive the gathered data
- Present current and past data in visually comprehensible and unambiguous visualizations
- Offer instruments for the examination and interpretation of data.
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Administration
Comprehensive energy management in manufacturing requires not just a data processing system, but also a large administrative and social component, since the reduction of energy use entails implementing changes. Historically, plants have depended on passive techniques, such as installing a more efficient motor or insulating a hot tank, to decrease energy use. These measures result in automatic energy savings once implemented. Nevertheless, effectively persuading operators to report compressed air leaks or to enhance process control, both of which need their continuous involvement, requires clear explanation of objectives and some retraining.
To achieve the objective of reducing energy consumption, it is essential that senior management actively participate and demonstrate unwavering dedication. Moreover, it is important to effectively convey the objectives and initiatives of the program to all individuals inside the organization who will be executing them or will be impacted by the alterations. Education and comprehension are essential for the overall effectiveness of energy management in manufacturing industries.
Examine the data to assess the efficacy of the implemented modifications
After establishing objectives and implementing changes, it is possible to examine the data to assess the efficacy of the implemented modifications or smart energy management. Regardless of the success of a set of activities, it is likely that new ideas for reducing energy use will emerge, and further modifications may be put into effect. Due to alterations in the process and fluctuations in the cost and accessibility of external energy resources, the optimization of energy use must be a continuous endeavor.
Implementing a Power Management System Using ISO 50001
An effective method for implementing an industrial energy management program. It involves the use of the ISO 50001 recommendations. The International Organization for Standards provides it and focuses on energy conservation. This standard specifies the necessary criteria for establishing policies, methods, tools, and strategies. It aims at successfully executing an efficient energy management program.
The standard aims to include energy management in every aspect of organizational culture. It also prevents the implementation of an “energy-saving program” from becoming a temporary project limited to certain departments, such as engineering or accounting. Furthermore, the ISO standard mandates not only the participation of the whole firm but also the ongoing improvement of both the program and the actual energy conservation. The ISO 50001 standard employs a methodical and organized strategy to attain enhancements in energy performance via the implementation of a “Plan-Do-Check-Act” improvement framework.
Plan
To start the implementation of an energy program, the first stage is to establish a comprehensive strategy. This process may be delineated into two distinct parts. During the first stage, it is crucial for senior executives to fully endorse the idea of energy reduction and establish a comprehensive plan for its execution. The framework includes the establishment of boundaries, formulation of policies and objectives, and assembly of a team to oversee or carry out the necessary tasks. Once all these components are properly established, it is crucial to effectively convey the significance of the ongoing activities to all members of the company.
The second stage of the planning process is the gathering and evaluation of data. The objective of this study is to comprehend the present operational condition and pinpoint regions with notable energy use. Using this information, techniques for decreasing energy use are suggested.
Do
During this phase, tangible measures for energy management and reduction come into practice. At this juncture, it is possible to get state-of-the-art, energy-efficient equipment. Accountable personnel are designated and employees undergo retraining if required. Alternative external energy sources may be discovered and used to address economic or environmental considerations.
Verify
An energy management program needs a systematic approach to assess its efficacy. Internal audits should assess the administrative components of the program to identify any shortcomings and ensure proper implementation. It is necessary to evaluate the energy statistics to assess the program’s efficacy in terms of real energy use. It is necessary to rectify any shortcomings in the management or execution of the program. Findings go on record and reach senior executives.
Act
An essential component of an ISO 50001 energy management program is the concept of ongoing improvement in energy efficiency. Hence, the upper echelons of an organization need to establish a systematic procedure for regularly assessing and appraising the company’s existing energy program and its energy efficiency. Management must proactively seek novel prospects and implement measures for improvement.
ISO 50001 Certification
To get “ISO 50001 certification,” it is necessary to undergo a thorough evaluation and certification process conducted by an authorized third-party organization. This evaluation covers all the processes and paperwork associated with an energy management program. Moreover, accreditation necessitates that a firm effectively achieves its internally established objectives for energy reduction. Although an ISO-certified energy program may be more intricate than an internally produced program, it offers the benefit of external assistance and verification, which may enhance the internal significance and likelihood of success of a program.
Furthermore, ISO accreditation can have a favorable impact on marketing efforts. It serves as a conspicuous demonstration to all individuals inside and outside a corporation. It also includes its clientele, and the corporation dedicates itself to conserving energy and mitigating the environmental consequences of its activities.
Concluding Remarks
Energy management is the holy art form in manufacturing. It is where raw ingredients take the shape of creative goods. Skilled craftsmen orchestrate a beautiful symphony. The delicate balance between electricity usage and resource efficiency weaves sustainability into manufacturing facilities. Technology and strategic insight lead industrial energy management like heavenly bodies in a cosmic ballet. Every watt of power becomes a diamond in this heavenly dance, revered for its potential to brighten a greener, more sustainable future.
Energy management rises above manufacturing to environmental care among the buzzing equipment and churning gears. Manufacturing plants, like the ancient guardians of nature, incorporate energy conservation into their operations. In the ethereal glimmer of dawn’s first light, the industrial landscape wakes to a new day, as renewable energy sources soothe and revitalize the air. The industrial sector shines a bright light on sustainable innovation, from solar panels that absorb the sun’s heat to wind turbines that harness the atmosphere’s forces.
Energy management’s symphony plays out like a huge orchestra under manufacturing buildings’ high ceilings. Manufacturing processes become a dance of efficiency when modern sensors, predictive analytics, and automation technologies work together to reduce waste and improve production. Manufacturing facilities adopt comprehensive energy management strategies as change whispers across the industry. From lighting system optimization to energy-efficient gear, every area of manufacturing shows dedication to sustainability.
Energy management is the shining jewel in contemporary production. It points the route to a future where innovation and environmental care are one. Industry leaders, legislators, and environmentalists need to work together to change the manufacturing sector.
