Production line efficiency is key to food and drink manufacturers - discover 10 ways to cut energy costs and improve plant efficiency.

1. 10 WAYS TO REDUCE
WASTE ENERGY IN YOUR
PRODUCTION LINE
www.energ.co.uk/CHP
Follow these 10 tips to improve production line efficiency in
food and drink manufacturing and cut energy costs in your
plant as well as meeting industry sustainability targets.
CO2

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Reducing energy waste in manufacturing and improving
production line efficiency is essential if manufacturers are to
comply with mandatory greenhouse gas emissions regulations
and EU targets - and it’ll also help lower energy bills.
Here are 10 ways that energy and facilities managers can
improve the efficiency of their production line.

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Optimising the use of refrigeration and chilling, which
can account for up to 50% of a site’s energy costs.
• Prevent overcooling to minimise energy costs and improve efficiency.
• Maintain systems and pipework - ensure they are not blocked, dirty
or leaking.
• Upgrade or replace inefficient equipment.
• Switch off lighting in refrigeration areas when not in use.
• Keep refrigeration doors closed and prevent cool air from escaping.
1.

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Regularly maintaining boilers and heating distribution
systems. Poorly operating boilers add 30% to heating
costs.
2.
• Ensure burners are working efficiently, or replace them.
• Switch off burners when not required - install automatic controls.
• Upgrade or replace inefficient boilers to improve efficiency in the
production line.
• Fit heat recovery systems to boilers (especially gas),
e.g. reclaim heat energy for use in process preheating.
• De-steam non-critical systems and replace with
less expensive hot water systems.

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Ensuring pipework is well insulated (refrigeration,
heating and steam systems).3.
• Pipework should take the shortest route to minimise potential energy
losses.
• Insulation should be in good condition.

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Operating costly compressed air systems efficiently.4.
• Switch off idling air compressors, as they can still use 40% of their full
load.
• Reduce the system pressure wherever possible.
• Carry out regular maintenance.

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Improving lighting systems.5.
• Fit high efficiency lighting and controls - this can reduce energy costs
by 30%.
• Fit motion sensors in unoccupied areas to automatically switch off
lights.

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6.
• Switch off motors when not in use - fit auto sensors to control
operation.
• Install higher efficiency motors.
• Fit variable speed drives to pumps and fans.
Correctly sizing motors and drives for their
application. This can reduce running costs by 3%-5%.

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7.
• Ensure water systems are well maintained.
• Recycle process water.
• Fit self-closing taps.
Initiating water saving measures.

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8.
• Ensure process equipment is utilised and controlled efficiently.
• Equipment should be regularly calibrated.
Using process measurement and control – this can
cut energy costs by up to 10%.

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9.
• Fit meters to electrical equipment to monitor system efficiencies and
determine where further energy savings can be made.
• Turn off equipment when not in use, i.e. at night and on weekends.
Integrate energy management systems.

12. www.energ.co.uk/CHP
10.
• Achieve energy cost savings of up to 40% and reductions in CO2
emissions of up to 30%.
• Install CHP as a replacement for inefficient boilers or alongside
existing boilers – generate efficient electricity and heat energy from a
single on-site process.
Consider Combined Heat and Power (CHP).

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