5 tips on how to save electricity in industry

Energy consumption is one of the highest impact factors on the revenue of medium and large industries and companies. Figuring out how to save electricity in the industry is therefore both a challenge and a necessity for companies.  

According to the study “How much does electricity cost for the industry in Brazil?”, published by Firjan in 2018, the industrial sector's spending on electricity can account for more than 40% of total production costs.  

Bearing in mind the importance of saving energy and the impacts of this cultural shift on company revenue and management, we have prepared this article. In it, you will find some tips on how to save energy in your industry, achieving greater energy efficiency and managing the resource strategically.  

Energy saving and energy efficiency: understanding the concepts

Saving energy means effectively reducing its consumption. To figure out how to save electricity in the industry, a company needs to rethink how it carries out its processes and make adjustments with the ultimate goal of generating lower kWh consumption.  

When we talk about energy efficiency, on the other hand, we go a step beyond saving energy. Here, what is at stake is the pursuit of a way to guarantee maximum equipment efficiency with the minimum possible expenditure. Did you get the difference? Let's dive a little deeper.  

Energy efficiency actions go beyond changing light bulbs and replacing equipment. They are the result of deep analyses of how the company operates. To make it clearer, check out this example:

Suppose an ice cream factory is looking to save energy. In this case, the study will focus on the equipment and how it can be adapted or replaced to consume fewer kWh. The result of this research might be, for example, the need to replace freezer lights with LED bulbs, which consume less energy.  

If the same company is looking for energy efficiency, the study will be a bit different. The research will try to find out if there is any way to optimize the use of existing equipment by changing, for example, how products are stored, where the machine is located, its operating time, or by making fine adjustments to the temperature.

A practical example that brings the concept of energy efficiency to a larger scale is the ranking of countries with the best energy efficiency policies. This is a study conducted by the ACEEE (American Council for an Energy-Efficient Economy) in 2018, based on 36 different metrics to assess each country's national commitment to saving energy and implementing energy efficiency policies.

In it, Brazil ranked 20th among the 25 countries studied. The top positions were held by Italy, Germany, France, the United Kingdom, and Japan. But even though our country is not an example in this regard, you can make a difference by optimizing energy consumption in your business. To do this, simply combine saving actions with the pursuit of energy efficiency.

Sounds complicated? Check out the next topic for some tips we've put together for industries, which can also be adapted to other types of businesses.

How to save electricity in your industry?

There are certain attitudes that can transform an industry's energy consumption reality. These are changes ranging from simple actions to more complex investments. All of them, however, have a positive impact on energy savings. Check them out:

Optimize lighting

Lighting expenses account for a considerable slice of companies' electricity bills. This is because the electrical lighting system is often old and rarely undergoes optimization maintenance.  

One of the best ways to optimize electricity consumption in lighting is by replacing old systems with LED bulbs. These bulbs consume up to 60% less energy than incandescent bulbs.  

Another effective way to improve lighting is to assess the available space in the company and structure it around natural light inlets. Partitions, equipment, tall shelves, and dark colors hinder light entry into environments and create a dependency on the electrical lighting system.

Perform maintenance and equipment replacements

Constantly used machinery requires periodic maintenance, especially when they are old. Over the years, such equipment tends to lose efficiency, consuming more electricity to perform its functions.  

Reconditioning electric motors or rewinding them, for example, can be a crucial practice in reducing the inefficiency of this type of equipment. Therefore, it is important to recognize when it is time to replace this equipment with a new one. In some cases, the extra energy expense due to long-term use and the existence of an older item makes the investment in a more current and economical version worthwhile.  

But remember: when making a replacement, the ideal is to give preference to high-performance equipment that features the Procel Label (Inmetro's Electric Energy Conservation Program), indicating its consumption level.  

Evaluate ventilation and heating systems

In an industry, ventilation and heating equipment have a much more strategic function than it seems. They are responsible for controlling temperature levels for a series of equipment.

Therefore, before setting up the production sector, it is essential to understand what the ventilation and heating demand for that sector will be and what the primary function of the equipment is: heating or cooling.  

Overloaded equipment tends to consume higher levels of energy. Therefore, it is necessary to strategically analyze equipment management, activating them at specific times based on the peak utilization hours of productive machinery.  

Invest in renewable energy  

Looking for alternatives that reinforce the company's commitment to waste reduction and environmental conservation is a doubly interesting strategy. First, because it helps save electricity in the industry. Second, because it positively impacts the environment we live in.  

It is estimated that between 2013 and 2017, the Free Energy Market generated R$ 83 billion in savings for its consumers. For this reason, it has been attracting more and more medium and large-sized companies, such as industries, retailers, supermarket chains, shopping malls, and commercial buildings.

By contracting energy in the Free Market, consumers can not only negotiate energy prices and contracts directly with generators and traders, but they can also opt for renewable sources. This allows for energy savings and environmental care with a single action.

Check for Reactive Consumption

Reactive consumption refers to reactive energy, generated when equipment fails and malfunctions. In this case, some energy utilities charge a kind of fine for the poor use of electricity—meaning inefficiency—since this energy is being wasted.

The name of this charge on the bill may vary depending on the energy distributor, and it is their duty to notify the consumer about what happened.

If you find that this is happening in your company, carefully evaluate all installations and correct the problem as soon as possible. Then notify the local utility about the steps you have taken and request an evaluation in order to have the charge removed.

Where to start saving electricity in the industry?

As important as figuring out how to save electricity in the industry is knowing how to get started. Check out some suggestions below:

• Develop effective management of consumed energy, focusing on consumption reduction opportunities;  

• Monitor consumption. The deeper the understanding of the industry or equipment's consumption particularities, the greater the chances of finding efficiency improvement points and optimizing energy use;

• Optimize consumption by taking peak and off-peak hours into account. Peak consumption, because it occurs during times of high energy demand, has much higher transmission and energy tariffs. Try to concentrate high energy demand activities during off-peak hours, which have lower charges;

• Raise awareness and involve employees so that they also put reduction measures into practice;  

• Evaluate the possibility of migrating to the Free Energy Market and simulate the savings you can achieve by comparing this market to the Regulated Market.

So, how about starting to save electricity in the industry today? We hope this content has been useful to inspire some changes and optimize resources in your business.

To learn about this and other energy-related topics, check out Serena Talks, Serena's blog. Until next time!