This document provides an overview and instructions for using the Energy Saving Scheme - Energy Management and Benchmark Tool (ESS-EMBT). The ESS-EMBT is an Excel-based tool that allows companies to track energy consumption, calculate energy indicators, analyze consumption trends, and benchmark performance. The summary includes: 1) The ESS-EMBT collects production and energy consumption data from companies. It then calculates indicators like specific energy consumption and compares performance to benchmarks. 2) Setup requires enabling macros and inputting company/segment data, energy invoices, and production figures. Results include consumption graphs, regression analysis, and benchmarking. 3) Benchmarking compares company indicators to averages from 27 EU companies in 42

1. Co-funded by the Intelligent
Energy Europe Programme of
the European Union 1

2. Co-funded by the Intelligent
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the European Union 2
Overview
 Introduction
 Manual
System Requirements
Analysis
Results
Benchmarking
Introduction – Manual

3. Co-funded by the Intelligent
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Manage and Benchmark energy consumption in the company by maintaining
an updated energy bookkeeping
The tool assists companies to find answers to the following questions:
 What is the energy content of my product?
 What is the carbon footprint of my product?
 What is the specific energy cost of my product?
 How do I evaluate my consumption on a regular basis?
 How is the company doing, energy wise, when compared with its
counterparts?
Purpose of the ESS-EMBT
Introduction – Manual

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The Energy Saving Scheme developed in the EU-project SESEC does provide
you with the following tools:
• Overall SESEC Approach
• EBMT (Energy Management and Benchmark Tool), based on Excel,
described in this presentation
• EDST (Energy Distribution Support Tool)
• SAT (Self Assessment Tool)
• Nine presentations on energy saving best practices:
• Supply Contracts and shifting – Grid
• Utilization - Production machines
• Compressed Air
• Steam and Heat Production
• Renewable Energy and Co-generation
• Lighting
• HVAC I (Heating)
• HVAC II (Ventilation, Air Conditioning)
• Vacuum, Cleaning
For more information consider [1] and [2]
Tools and resources available
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 Energy bookkeeping;
 Company’s global and/or segment energy indicators on a monthly and annual basis.
Indicators include:
 Specific Energy Consumption;
 Specific (Energy) Cost; and
 Carbonic Intensity.
 “Energy vs. Production” graphical analysis;
 “Energy Cost vs. Production” graphical analysis;
 Global and/or segment analytical calculation of energy consumption when
production is 0, the calculation of energy required to produce one additional unit and
calculation of the energy proportion that doesn’t contribute to production;
 Benchmark position based on calculated indicators globally and by process in each
segment.
Preview: Results to expect
Introduction – Manual

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Steps
1. Set the Scope
2. Setup the Excel
3. Perform the analysis (Input)
4. Interpret the results (Output)
5. Benchmark
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1. Set the scope
What do you expect to get from the ESS-EMBT-tool? E.g.:
 Analyze energy/consumption evolution
 Retrieve energy indicators
 Retrieve regression data analyses
 Benchmark consumption
Who in your company will work with the ESS-SAT-tool?
 You will need production data by segment, energy invoices of all sources
and data from ESS-EDST tool , if you want to get the maximum value
using the ESS-EMBT
What will be the next steps?
 E. g. Track energy consumption vs. production evolution in a monitoring
& targeting approach
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2. Setup the Excel
MS-Excel 2010 or later required
The most current version is available on www.sesec-
training.eu
Macros have to be enabled
The ESS-EBMT was developed using macros. You need to
enable macros in order to be able to fully use the ESS-EMBT
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2. Activate Macros
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3. Sheet: Introduction
All sheets are navigable but tool use
should follow a left to right order
Read the full intro, it will help to
understand tool inner works
Introduction – Manual
In this module we will use an
example of a theoretical
company named XPTO. This
company produces Socks that
are included in segment
“Underwear and Bras” and
Seamless T-Shirts that are
included in segment “T-shirts
and related - knitted”.
The main output from the
company are socks that
represent nearly 100% of the
production , T-shirts
represent a very small
percentage of production
being considered almost as
sample production.
The EMBT tool with the
example is also available in
SESEC’s website.

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Sheet: Production input
Introduction – Manual
Fill company data. All data
to be inserted is to be
related to the indicated year
Select the segments
produced in your
company, every selection
will enable segment specific
data input. Also fill the total
production data in units
(pieces).
The first sheet is the “Production input”
sheet. In this sheet you’ll be asked to
identify the company, the user, the year,
the produced segments and production
data. Production data is to be inserted in
units (pieces) and is subdivided:
- Total production (includes all segments);
- Segment production; and
- Process production (in each segment).

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Sheet: Production input (2)
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After selecting segments and introducing
the global production you are asked to
input segment specific production, in this
example tool only asks data for
“Underwear and bras” and “T-shirts and
related – knitted” production because
these were the selected segments.
Note that if you were inputting data for
one segment only, you would be
doubling production data input (Segment
production = Global production). This
double input is important for
benchmarking purposes so input all
required data if it looks like redundant
work.
If you only want to have a global
approach to energy management and
have no interest in benchmarking this
and the next table need no filling.

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Sheet: Production input (3)
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After selecting segments, introducing the global production and input segment specific production,
you are asked to input production data concerning specific processes on each selected segment.
Note the “August” cell in both segments:
- In T-shirts, knitting production is “0”, although 1.000 units were finished. In this case 1.000 units
from July were finished in August.
- In Underwear, knitting production is “0”, although 233.000 units were finished. In this case all
knitting was outsourced and then finished indoors.
Energy results will be affected by these events and influence benchmarking.

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Sheet: Energy input (1)
Introduction – Manual
The next sheet is the “Energy input” sheet, here you will be asked to input energy data that can be
retrieved from invoices, it will also ask for the energy distribution by segment. The energy distribution
by segment this is one of the outputs from the Energy Distribution Support Tool (EDST) also available
in the ESS toolbox.
This sheet also provides an energy resume that allows you to compare the various energy sources
used in the company.

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Sheet: Energy input (2)
Introduction – Manual
Input energy
consumption
and the
energy cost
without VAT.
The tool enables you to input up to 11 different energy sources including Electricity, Natural gas,
Heavy fuel oil (HFO), Thin fuel oil (TFO), Gasoline, Diesel, Coal (Bituminous), Biomass (wood), Liquid
Petrol Gas (LPG), Steam and Hot Water.
Steam and Hot water tables are only to be filled if the company buys them from an outside source,
i.e. cogeneration plant or district heating. If these are produced internally via, i.e., Boiler and/or water
heater you should not fill them.
Gasoline & Diesel tables are to be filled only if they are used indoors, i.e., emergency generators,
boilers, fork lifts, etc.

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Sheet: Energy input (3)
Introduction – Manual
This table is the energy
resume, here you can find:
- Total energy consumption
by source both in kWh and
toe;
- Consumption and cost
percentage of each source;
- Monthly total energy
consumption and CO2
emissions;
- Graphical analysis
comparing energy
consumption and energy cost
ratio.
Here, because energy sources
are reduced to the same
units, consumption analysis is
simplified and comparable.

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Sheet: Energy input (4)
Introduction – Manual
In this table the energy distribution is
to be inserted by segment. This
distribution is based on calculus that
include production machines and
auxiliaries technical data, it’s work
hours and work load, etc. These
results are available as one of the two
outputs from the Energy Distribution
Support Tool (EDST) also available in
the SESEC’s ESS toolbox.
In EDST there is a sheet called “Data
for EMBT”, so just copy data from
table 1 and paste it in this table.
Similarly to the “Production input”
sheet, if you only want to have a
global approach to energy
management and no interest in
benchmarking don’t fill this table
meaning that you don't need to use
EDST.

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Sheet: Results - GLOBAL (1)
Introduction – Manual
This sheet data be divided into three different
types of results, the first is the monthly graphical
energy analysis of “Energy vs. Production” and
“Production vs. Energy Cost” where it’s possible
to verify the evolution of consumption together
with production and analyze deviations.
Notice months May and August where deviations
are quite visible. Without a graphical analysis it
would be difficult to find, justify and correct
these deviations.

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Sheet: Results - GLOBAL (2)
Introduction – Manual
The second result is the statistical energy analysis
based on graphic regression analysis which
includes varied information:
- Global analytical calculation baseline
consumption (energy consumption when
production is 0);
- Global analytical calculation of energy required
to produce one additional unit;
- Global analytical calculation of the energy
proportion that doesn’t contribute to
production;

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Sheet: Results - GLOBAL (3)
Introduction – Manual
The third result concerns the energy
indicators:
- Specific energy consumption (SEC)
SEC = Energy / Production
- Specific energy cost (SC)
SC = Energy cost / Production
- Carbonic intensity (CI)
CI = Greenhouse gases (CO2) / Energy
These indicators are useful not only for
benchmarking but also for progress
evaluation after energy saving
measures are implemented. Indicators
lower as measures are implemented as
long as average production is
maintained. If production lowers too
much the indicators tend to skyrocket
regardless the amount of energy saving
measures implemented.

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Sheet: Results – SEGMENT (1)
Introduction – Manual
The sheet “Results - SEGMENT” returns the same outputs as “Results - GLOBAL” sheet, but it’s segment
specific. So if a company only has one segment, the results in SEGMENT are exactly the same as in
GLOBAL. In our example there are two segments so the analysis is segment specific, you are be to
compare the “Energy vs. Production”, the “Production vs. Energy Cost” graphs, all the statistical energy
analysis based on regression analysis and the segment specific indicators on all segments.

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Sheet: Results – SEGMENT (2)
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Sheet: Results – SEGMENT (3)
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Important note:
The conversion factors that were used to obtain values in toe and in kWh are universal in SESEC, i.e., in
order to develop an international benchmark the different conversion factors used in the various EU
countries were normalized. The values ​​used in EMBT can be found in the "Guidance document for the
ESS Self Assessment Tool" and "ESS guide for companies" documents available in SESEC's website.

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Sheet: Benchmark (1)
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SESEC’s original benchmarking is based on data retrieved from 27 EU companies that represent 42
product groups. These 42 products are the foundation for comparable data on the 7 production
segments that compose the SESEC ESS, T-shirts and related – knitted; Shirts and blouses – woven;
Trousers and skirts (casual and denim) – woven; Suits & overall jackets – coats; Pullovers flat knitted;
Underwear & bras; and Technical products.
The value that is benchmarkable within SESEC is the specific energy consumption (SEC), this indicator
represents the amount of energy needed, globally and/or process/sector specific, to produce one
production unit, so in EMBT the benchmarkable data available comprehends, in each segment, the
specific energy consumption, kWh/un, on:
– Weaving;
– Knitting;
– Spreading + Cutting + Sewing;
– Embroidery;
– Printing;
– Finishing;
– Lighting;
– Compressed air;
– Steam/Hot water generation;
– Total Energy.
Although processes benchmarking is important results
can be extremely variable specially due to factors like
HVAC use, technology specificities, etc. so results can
be disheartening. When benchmarking total
energy, factors that produce a negative deviation in
some processes are countered by positive ones in
others meaning that total energy (SEC by segment)
benchmarking becomes the most important one when
comparing indicators.

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Sheet: Benchmark (2)
Introduction – Manual
In these tables benchmark
base data is to be inserted,
note that you can only
benchmark one segment at
the time (data on the right
refers to segment Underwear
and bras).
This distribution is based on
calculus that include
production machines and
auxiliaries technical data, it’s
work hours and work load,
etc. These results are the
second output from the
Energy Distribution Support
Tool (EDST) also available in
the SESEC’s ESS toolbox.
In EDST there is a sheet called
“Data for EMBT”, so just copy
data from tables 2 &3 and
paste it in these tables.
Similarly to the “Production input” and “Energy input” sheets, if you
only want to have a global approach to energy management and no
interest in benchmarking don’t fill these tables (you don't need to
use EDST).

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Sheet: Benchmark (3)
Introduction – Manual
Simply select the segment
o benchmark and check
the results, these appear
both numerically and
graphically
When analyzing benchmark
results you must have a
critical approach and don’t
take results literally. In the
example we can see that
compressed air has a
tremendous deviation, this
doesn't mean that the
example company is very
inefficient, it means that, due
to the knitting process it’s
much more compressed air
dependent than the best
benchmark value in SESEC’s database, nevertheless it’s an area worth further analysis. Obviously the
global result is affected by this compressed air dependency and returns a higher indicator than the
best benchmark value in the database.

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Sheet: Benchmark (4)
Introduction – Manual
In the previous slide you surely noticed that many values are unavailable for benchmarking and are
represented by a “No Data” message in the benchmark table, this means that the database has a lot
of room to grow.
Although 42 product groups represents a good base it’s important to strengthen the benchmark
database. With this objective in mind the SESEC consortium urges the user to send it's company's
results to his country specific SEP (single entry person). To help increase the database print screen
the final table on the Benchmark sheet (see image below) and mail it to your country specific SEP’s
email, e-mails are available in SESEC’s training platform, http://www.sesec-training.eu/
All data will be treated confidentially, the company will be coded and can only be identified by the
SEP.

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Readings
 [1] CITEVE (2013): Critical Energy Saving Points for the Clothing Manufacturing Process/Factory
Environment, Deliverable D3.1
 [2] CITEVE (2013): O3.2 “Energy Saving Scheme (ESS) Guide for Companies” and O3.5 “Guidance
Document”
 [3] GHERZI (2013): Energy Data, Deliverable D2.2
 [4] DITF (2014): Euratex Overall SESEC Approach, presentation available on www.sesec-training.eu
 [5] CITEVE (2014): EDST (Energy Distribution Support Tool), presentation available on www.sesec-
training.eu
 [6] ENEA (2014): SAT (Self Assessment Tool), presentation available on www.sesec-training.eu
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Pictures
 Slide 8 – Dennis Skley: *grübel* – URI: http://www.flickr.com/photos/dskley/8627475625/sizes/z/in/photostream/
License: CC BY-ND 2.0 (http://creativecommons.org/licenses/by-nd/2.0/legalcode)
 Slide 9 – Carissa Rogers: kid to do list, list, Be happy and go home – URI:
http://www.flickr.com/photos/rog2bark/3437630552/sizes/m/in/photolist-6eLKNh-c1mn5W-9Lcbki-9jeZKu-CdE9B-
6tQG1N-8cuPQg-6oCMfR-5R2t5b-9uCMNF-7WWKna-82Z8Cz-87uSWj-839wC-8QW9Yq-7pHc1U-6qsYHC-gu1Ra-
7Jq5QH-7Mfehz-7VWPxJ-6J37Hp-4QCVn9-8QzzeL-8w3ARY-5JaQRk-5wvNsm-fMnd2-ffgRgs-4yar1X-dr9xUw-dJLTso-
3bLKoc-5sane8-eT8xC-5QjTMr-55xTxK-iYZum-i8xKL-61m8xK-6YzqVs-7JKQkd-5SyRgw-4VSKqq-avZUVo-4ZwxHC-3svSV-
4qU25r-4sCr3S-PVLFS-5rMwqS/ License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)
 All other pictures (except the logos) are screenshots of the EMBT-Tool by SESEC CC BY-SA 2.0
(http://creativecommons.org/licenses/by-sa/2.0/legalcode),
Introduction – Manual