To improve energy efficiency in manufacturing plants, companies should analyze their energy usage, implement best practices, and encourage efficiency among employees. Analyzing factors like peak demand, machine consumption, and power quality can identify areas to reduce waste. Installing variable frequency drives, upgrading lighting and HVAC, and using renewable energy can significantly cut costs. Educating employees about efficiency benefits both the environment and a company's bottom line through lower bills and improved competitiveness. Energy efficiency is a form of quality management that eliminates production waste while benefiting both businesses and communities through reduced pollution.

1. To improve energy efficiency
of manufacturing plant
Bring your Green to Work

2. Introduction
 Today in this running era, with the raising
prices of commodities of daily needs
there is also an acute rise in the
electricity consumption unit prices.
 To cut these prices, the only solution to
minimize the electricity bills there is need
to adopt the way of energy efficiency.
 The energy efficiency in the
manufacturing plant comes naturally
because it is application of Total Quality
Management which eliminate waste in
the production process.

3. Some facts
 According to the National Association of
Manufacturers they have set a manufacturing
institute which will help manufacturers to
save energy.
 NAM members recently shared their energy
saving secrets. During the survey 400
manufacturers participated which revealed
that out of them 85% of the manufacturers
made energy efficiency improvements in the
last 5 years. (according to Canadian
government facts)
 This simply measures that reducing the use
of 10% of the energy can save as much as
$18 Billion of energy consumption cost.

4. Facts of energy efficiency in
India
 India ranked 4th in term of energy
demand, accounting world’s 3.5% of
world commercial demand 2014.
 Industries are facing challenges of the
rising cost of energy and fuel.
 Industrial energy efficiency is of prime
importance for India according to
Energy conservation Act of 2001 and
Bureau of energy efficiency.

5. How we can achieve the state of
Energy efficiency and make the
manufacturing plant energy
efficient?

6. Analyzing factors before process
start-up
 Peak energy demand identification: - peak
energy demand of the manufacturing plant can
be calculated by checking the electricity bill of the
current billing period. But the exact demand
cannot be predictable in the bills, this can only be
done by checking the sub meters which are
installed in every department and it is not stable
as everyday operation of machines is depended
on production plan.
 Checking the loses: - The loses in a
manufacturing plant can be determined from the
start point of electricity i.e is the transformer and
after that wastages in the plant like employees
running the machines idle waiting for the parts to
work on and other leakages in the distribution
line.

7. Continue…
 Weekend energy use: - This is also an
important factor while predicting the causes
of energy consumption at weekends. The
calculation of working hours of the machines
and the employee running the machines and
the production demand.
 Consumption of each machine: - The
energy consumption of every machine and
even the CFL’s and Tube lights consumptions
is required.
 Power factor balance: - this is a main part of
the analyses. This shows that whether the
power factor is perfectly maintained between
0.91 to 1.00 values of power factor.

8. Continue…
 Compressed air wastage and usage: -
This is a huge aspect to analyze as the
manufacturing of any part cannot be
done without compressed air.
Compressor play a crucial role in
manufacturing line.
 Calculation of voltage and current: -
this is part which shows the details of on-
load and off load consumption of
amperes by the machines. This is
important that when the voltage and
ampere fluctuates during the mechanical
movement of power presses and other
machines.

9. Best practices for making a
manufacturing plant energy
efficient Increase the efficiency of all motors and
motor driven system: - the higher the
efficiency the lower the operating cost. The
more motors a manufacturer upgrades, the
more energy – efficient the manufacturing
process will be. This will also effect the total
operating cost and become more competitive
in the market.
 Key to success: - regular maintenance
keeps motors running efficiently and identifies
problems before a breakdown. By
replacement of low efficiency motors with the
high efficiency motors.

10. Continue..
 Installation of VFD Drives on large
energy consuming machines: - the
installation of VFD drives will help in
controlling the motor operation and
lowered the start off consumption. This
also protect the motors from unusual
breakdowns like contactor problems in
the start delta starter of compressor.
 Key to success: - the key to success is
to check the no- load and on-load
consumption of heavy machines and
also the consumption of energy during
the start up.

11. Example of compressor
 A 350 cfm compressor consumes
When no drive was installed
 No- load current- 60 A
 On load current – 112A
When VFD drive got installed
 No load current reduced to 35A
 On- load current reduced to 92 A
 This increased the idleness of the
compressor by stopping the wastage
in the distribution of line of air.
Improve the efficiency and reduce the
cost.

12. Improving the building
lightings
 Installing high-efficiency lighting systems
and using day lighting will not only lower
your lighting costs, it will also improve
lighting quality. Think of day lighting has
"free" light that may also improve worker
performance, just as it’s been shown to
improve students’ academic
performance. The sleeper bonus here is
increased productivity.
 Key to success:- Combining a lighting
improvement project with other energy-
efficiency projects will keep costs down.

13. Example
 If there are 170 CFLs installed in the
company each of 85watt then the
consumption of those cfl will be
 Energy consumption: - 170 х 0.085 х
12hrs. Is equal to 173.4 units per day.
 If we save the day time consumption then
we could save around 4.5 lakh rupees per
year.

14. Upgrading the HVAC
equipment
 Higher-efficiency HVAC equipment
and more effective computer control of
how and when that equipment is used
can substantially lower your HVAC
costs. Even simple steps, such as
reducing HVAC output on weekends
and at night, can make a big
difference in overall plant and office
energy-use that can only add to a
manufacturer’s competitiveness.

15. Use of Renewable sources of
energy
 This can make a huge
difference in the cost
of the energy
consumption. Like the
use of sun light to
produce electricity and
can use that energy for
the day time purpose
will help in reducing
the bills considerably.
Although the initial cost
for these kind of
project is high but the
outcome of this is very
fruitful.

16. Encouraging the employees to
use the required amount of
energy
 Educating the employees working in
the organizations and telling them the
pros and cons of wasting the energy in
the future will help companies to
reduce the power bills. This
awareness can make a huge
difference in changing the mentality of
the people and raise them towards
Greener India.

17. Benefits of energy efficient
manufacturing plant
 Improving business competitiveness - Energy
costs affect a business's bottom line. Businesses
that control their energy consumption enjoy lower
heating, electricity and transportation costs.
 Increasing energy available for export
 This helps in reducing the power bills which
further increase the comfort level of the
manufacturers.
 Reducing local air pollutants - Energy
efficiency can reduce the amount of local air
pollutants that can come from sources like oil or
wood. These are separate from greenhouse gas
emissions and include fine particulate matter in
the air as well as other chemicals, such as
sulphur dioxide, that are harmful to human
health.

18. Thank you