"Mr. Weber, energy costs have already risen again by 23% in the last quarter!"
The controller confronted the production manager of Metallverarbeitung Schröder GmbH with this bad news. A situation that many manufacturing companies know only too well. The reflex thought: new, more energy-efficient systems are needed. But before you make any major investments, it is worth taking a closer look at the optimization potential of your existing infrastructure.
Uncovering hidden energy guzzlers
In most production facilities, there is considerable potential for savings that can be realized without new purchases. A medium-sized mechanical engineering company was able to reduce its energy costs by a considerable 18% - solely by optimizing the control and use of existing systems.
The first step? Systematic energy mapping.
- Identify the top 5 consumers in your company
- Analyze their load profiles over a representative period of time
- Document running times and power consumption in various operating states
"We were surprised that our compressed air supply consumed more energy than the actual production machines," reports Michael Weber on his findings.
Where is typical optimization potential hidden?
Intelligent control instead of manual switching
Many systems run longer and at a higher output than necessary. Thanks to adapted control programs and automated shutdowns during production breaks, Schröder was able to save 7% of energy alone.
Capping peak loads - the underestimated source of costs
Did you know that your grid usage costs are often determined by a few load peaks per year? Coordinated start-up control of several large consumers can dramatically improve your load profile.
How can existing systems be optimized?
- Modernization of the control technology
- Load management through intelligent switching programs
- Parameterization according to actual requirements instead of factory setting
- Optimized operating times through production planning
"The nice thing about control system optimizations: They require comparatively little investment and often pay for themselves within a few months," explains the production manager.
What does your system planning have to do with energy costs?
Surprisingly much! Well thought-out electrical planning takes into account not only pure functionality, but also energy aspects:
- Correct dimensioning of cables reduces transmission losses
- Optimized control cabinets avoid unnecessary cooling energy
- Intelligent control logic enables demand-driven operation
At Schröder, the revision of the control plans with an experienced electrical designer resulted in further savings of 5% - without replacing a single motor.
Have you already exploited this hidden potential?
- Standby consumption during non-production times
- Start-up control of load-intensive units
- Compressed air and cooling water supply according to actual demand
- Optimized parameterization of frequency inverters
- Demand-based lighting control
For Michael Weber, the journey has paid off: "We have reduced our energy costs by a total of 18% within six months - without purchasing a single new machine. That corresponds to an annual saving of 142,000 euros."
The first step towards optimizing energy costs is not to replace appliances, but to take a closer look at your existing infrastructure. With professional support in the analysis and optimization of your electrical systems, amazing savings can be made - with manageable effort and a quick return on investment.
