Industrial and commercial manufacturing firms face significant challenges when it comes to managing energy costs. As of 2022, 3,600 manufacturing facilities, accounting for 14% of the sector’s US footprint, were enrolled in the DOE’s Better Plants program to meet energy reduction goals. Among the biggest opportunities for improvement are inefficiencies in HVAC systems, exhaust systems that filter out harmful manufacturing byproducts, and equipment shutdown procedures that waste energy during off-hours.

High energy costs can erode profit margins and reduce the overall competitiveness of a firm. Operationally, inefficient systems can lead to increased maintenance costs, more frequent equipment breakdowns, and a shorter lifespan for critical assets. Plus, non-compliance with regulatory standards for HVAC and exhaust systems can result in fines and legal issues, adding to the financial burden. 

Bigger Challenges Call for Big Thinking

Postponing solutions for these challenges can lead to substantial financial and operational repercussions. While some firms may already be attempting to address these issues, they often find limited success due to a lack of comprehensive strategies or guidance on how to incorporate them. 

Overcoming these challenges requires efficiency in more than just mechanical systems. We find that a three-pronged approach focused on people, technology, and processes creates the mechanism to affect organizational change broadly, accelerating the pace of project execution and, ultimately, cost reduction. Early identification of cost-effective efficiency measures builds momentum and provides examples of successful implementations and their impact. By leveraging the expertise of an independent energy efficiency consultant like Mantis Innovation, firms can achieve profound and timely improvements in their energy management strategies. 

Breakdown of Major Energy Efficiency Challenges Manufacturing Firms Face

A manufacturing plant’s process-related heating and cooling, air compression, HVAC, and exhaust systems are critical for its operational strategy and productivity. However, each poses its own challenges that can become strategic plunder if not properly maintained.

Here’s a breakdown of each of these systems and their failure points:

01 Process-Related Heating and Cooling

Process-related heating and cooling systems are essential for many manufacturing operations, but they can pose challenges:

• Inefficient Delivery Methods: Using outdated or inefficient methods to deliver heating and cooling can lead to excessive energy consumption. Exploring more efficient delivery methods can result in substantial energy savings.
• Heat Recovery: Many manufacturing processes generate excess heat that can be recovered and reused. Failing to implement heat recovery systems can result in missed opportunities to reduce the need for additional heating and lower overall energy consumption.
• Facility-wide Systems Integration: Ensuring your heating and cooling systems are well-integrated with other energy management systems can optimize energy usage and improve overall efficiency. Poor integration can lead to energy waste and suboptimal performance.

02 Air Compression

Air compression systems are widely used in manufacturing facilities to power equipment, material handling, cleaning, cooling, and other uses. However, they can be significant energy consumers if not properly managed. 

• End-Use Inefficiencies: Assessing the end uses of compressed air and identifying opportunities to reduce waste can lead to significant energy savings. This includes fixing leaks, optimizing pressure settings, and ensuring that compressed air is used only where necessary.
• Poor Maintenance: Regular maintenance is crucial for ensuring efficient operation. Neglecting maintenance can lead to leaks, pressure drops, and increased energy consumption.
• Lacking Energy Recovery: Energy recovery systems for air compressors can capture and reuse waste heat, further improving overall energy efficiency. Without them, valuable energy is lost, increasing operational costs.

03 HVAC System Inefficiencies

HVAC systems are critical for maintaining a comfortable and safe working environment but can also be a major source of energy waste. Several factors contribute to HVAC inefficiencies:

• Heating and Cooling Entire Facilities: Many manufacturing facilities use HVAC systems to heat or cool large areas, which can be highly inefficient if the systems are not properly zoned or if there are areas that do not require constant temperature control.
• Aging Systems: Older HVAC systems are often less efficient and more prone to breakdowns. They may not incorporate the latest energy-saving technologies, leading to higher energy consumption.
• Poor Maintenance Practices: Regular maintenance is crucial for ensuring that HVAC systems operate efficiently. Neglecting maintenance can lead to issues such as clogged filters, refrigerant leaks, and malfunctioning components, all of which can increase energy usage.
• Refrigerant Compliance: Compliance with refrigerant regulations is essential for both environmental and operational reasons. Using outdated or non-compliant refrigerants can lead to inefficiencies and potential legal issues.
• Improper System Calibration: Proper calibration of HVAC systems ensures they operate optimally. Incorrect settings can lead to overuse of energy and inconsistent temperature control.

04 Exhaust Systems

Manufacturing processes often produce harmful byproducts such as fumes, dust, and particulates. Efficient exhaust systems are necessary to expel these byproducts and maintain a safe and compliant work environment. However, several challenges can arise:

• Outdated Systems: Older exhaust systems may not be as efficient in removing harmful byproducts, leading to increased energy consumption and potential health hazards.
• Poor Maintenance: Just like HVAC systems, exhaust systems require regular maintenance to operate efficiently. Neglecting maintenance can lead to blockages, reduced airflow, and increased energy usage.
• Compliance with Regulations: Ensuring that exhaust systems meet regulatory standards is crucial for maintaining a safe work environment and avoiding legal issues. Non-compliance can result in fines and increased operational costs.

Starting (not so) Small with No/Low-Cost Opportunities

While optimizing these systems is not to be taken lightly, there may be opportunities just beneath the surface at your facilities. While these solutions won’t have the multi-fold impact of more complex projects, they can be immediately actionable, have swift ROI on your operating budgets, and provide the all-important momentum to kickstart your bigger energy efficiency projects.

Some of these no- and low-cost opportunities include:

• Considering more efficient methods of delivering the heat and cooling your manufacturing process needs
• Reducing waste in an air compression system by looking at the end uses for the compressed air first
• Creating an equipment shutdown protocol to reduce energy consumption during off-hours
• Reassessing your facilities’ current controls systems to improve the performance of HVAC and other systems
• Upgrading to the most up-to-date LED lighting fixtures for more efficient energy usage.

If you're uncertain about how to identify or implement these maneuvers, an experienced independent efficiency consultant would be able to assist you.

The Mantis Approach: Three-Prong Solutions for People, Technology, & Processes

Collaborative and Holistic Strategy

From working with hundreds of manufacturing clients with thousands of buildings across the US, we’ve found a three-pronged approach addressing their people, technologies, and processes to remedy their challenges.

Here’s a deeper dive into each aspect:

People

Leveraging internal expertise and fostering a culture of energy efficiency within the organization is transformational. Training staff and promoting awareness about energy-saving practices can lead to significant improvements in energy management. 

• Training Programs: Implementing training programs to educate staff about energy efficiency practices and the importance of following shutdown protocols.
• Identifying Energy Leaders: Where possible, identify energy leaders within the organization who can lead by example and promote energy-saving practices among their peers.
• Alignment on Strategies, Roles, and Responsibilities:  Ensuring that the key personnel are aligned with the program’s protocols will lead to their strategy’s success 

Technology

Implementing advanced technologies can optimize energy usage and improve system performance across a manufacturer’s portfolio. These technologies provide real-time data and insights that help in making informed decisions about energy management. 

• Building Management Systems (BMS): BMS can monitor and control HVAC, lighting, and other systems to optimize energy usage and improve efficiency.
• Computerized Maintenance Management Systems (CMMS): CMMS can help schedule and track maintenance activities, ensuring that systems are properly maintained and operating efficiently.
• Energy Management Systems (EMS): These systems can help reduce energy consumption and usage during peak demand periods, lowering energy costs and improving grid stability.

Within the manufacturing industry, leadership in digital transformation (and the technologies involved thereof) will be a deciding factor for firms’ future success. Our recent white paper “Modernizing Manufacturing” takes a broader look at the elements manufacturers ought to consider in their digital transformation strategy.

Processes

Regular system maintenance and timely restoration or replacement planning are essential for maintaining efficient operations and maximizing various systems’ useful lifespans. Developing and adhering to efficient shutdown procedures can also help reduce energy waste during off-hours. 

• Maintenance Schedules: Implementing regular maintenance schedules to ensure that systems are operating efficiently and to prevent breakdowns.
• Shutdown Procedures: Developing and implementing clear shutdown or turndown procedures to ensure that energy waste is minimized.
• Restoration and Replacement Planning: Planning for the timely restoration or replacement of aging systems to ensure that they continue to operate efficiently.

In Conclusion

While industrial manufacturing firms face significant challenges in optimizing their critical systems, they can also rest assured that the right approach can overcome them and achieve substantial energy savings. Better still, they don't have to do it alone or unguided. 

Mantis Innovation has provided the expertise and support needed to implement these strategies effectively. Our holistic, client-centered solutions for HVAC, facility asset management, and BAS are designed to extend in-house capabilities through managed projects and a programmatic approach to assets across any portfolio. Contact one of our experts today to learn more.