Energy Efficiency

Checklist
Manufacturing

Cost-saving measures, productivity

enhancements, and optimisation
opportunities
This checklist is a practical guide to help manufacturers establish energy efficient opportunities.
This checklist sets out of variety of opportunities with a wide range of costs (including many that are no-
cost) which can be taken when embarking on a process towards decarbonisation.
It focuses on the following areas:
1. HVAC
2. Lighting
3. IT and office equipment
4. Motors and drive systems
5. Pumps
6. Fans
7. Steam generation
8. Compressed air

Before you start this guide, you can set the foundations and start with purpose by:
1. Putting in place a climate action plan with regular feedback from stakeholders and staff around how to
improve your performance.
2. Assign energy management responsibilities to staff.
3. Maintain an updated action list of energy efficient opportunities.
4. Meet regularly and report on actions – provide the opportunity for staff feedback.
5. Start with a few simple actions from the low-cost list to see what savings you can make and then
progress towards more complex actions as you feel comfortable.
ACTION DETAIL COMPLETE?
GETTING STARTED

Measure Energy Monitor energy consumption (electricity, diesel, petrol) as well as water usage
Usage regularly to identify any unexpected increases.

Use EECA’s Energy Intensity Calculator to measure and keep track energy use
and emissions.

Compare monthly energy consumption data to the same month a year prior
and on a rolling 12-month basis to identify trends (i.e., increasing/decreasing
energy consumption).

Staff Engagement Educate staff about the importance of being as energy efficient as possible,
managing hot water use and turning off equipment when not in use.
• Run an introductory session to update staff about why it’s important
to save energy. You can also integrate information about your energy
programme into your sites induction training.
• Create a mechanism for contractors and staff to share their
suggestions with you. Make sure you respond to comments and act on
recommendations when feasible. You may even offer a reward for the best
energy-saving ideas.

Energy Choose the best power tariff that best suits the electricity load profiles in the
Management & plant. Similarly, reduce peak electricity loads by rescheduling processes so
Maintenance that they do not coincide with peak times.

Turn off lights, heaters, conveyors, and other electrical equipment when not in
use. Put time switches on lighting and heating.

Implement appropriate scheduling to regularly perform basic energy

maintenance by a qualified technician.

Check for leaking utilities (hot water/refrigerant/air).

Check lights are clean and free from dust.

Maintain and service motors used for air conditioners, refrigeration/freezing,

pumps, ovens, dryers, and conveyors to save energy and reduce wear and tear.

Reduce heat losses. Lag all hot pipes. Avoid long pipe runs.

Shed peak heat loads. Operate the minimum number of boilers needed and
reschedule heat loads so that the capacity of those boilers is not exceeded.

Ensure good door discipline in cold rooms. Keep doors on cold stores, chillers,
and freezers shut when not in use for loading.

Minimise air flow into freezer by maintaining seals around room doors.

Process Change Optimise material flows through the factory. Linear processes may reduce
production time, energy and cost.

Size boilers and heaters according to their use. (A correctly sized boiler may
operate at 85+% efficiency compared with 60-70%. A second-hand boiler may
cost more than a new one due to inefficient operation).

Allocate budget for preventative maintenance to save energy and prevent

disruptions from breakdowns and unscheduled maintenance.
ACTION DETAIL COMPLETE?

Asset register Develop asset register capturing key details, such as:
• Make
• Model
• Type of unit (i.e., screw or reciprocating)
• Age/ year of install
• Power rating
• Efficiency
• Operating temperatures

Implement asset replacement strategy focusing on more energy efficient

replacements.

NOTES

ACTION SAVINGS DETAIL COMPLETE?

HVAC

Clean evaporator Up to 15% of Dirty coils in a split unit raise the condensing tempera-
and condenser coils existing HVAC ture and can lower the efficiency by up to 15%. Cooling
energy use capacity can also drop by up to 7%. Cleaning the coils
only takes about an hour and improves the system's
efficiency.

Turn off the HVAC 10% - 70% of Heating and cooling unoccupied buildings wastes
when not needed existing HVAC energy. Most split units have timers that can turn the
energy use HVAC on before staff arrive in the morning and off after
business hours. Check that the timers are set to do
this.

Adjust temperature 2% - 10% of existing As well as being uncomfortable for the occupants,
setpoints HVAC energy use over-cooling a building during the summer or over-
heating it during the winter results in excessive energy
use.
LIGHTING

Check and adjust Up to 50% of light Light (lux) levels in many applications are typically
light levels circuit energy use much higher than required for the task. A basic lux
survey and delamping (disconnecting individual lamps,
usually fluorescent) to appropriate standard levels can
save a large proportion of lighting energy use.

Replace 80% of light circuit Incandescent lighting is highly inefficient and rarely
incandescent lamps energy use used in non-residential applications, as the alternative
with CFLs compact fluorescent lamps (CFLs) have a number of
advantages. For the same light output, CFLs use one-
fifth of the power of an incandescent, and also last
around eight times longer.

Replace MR16 30 - 80% of light Halogen downlighting and spotlighting is common in

halogen lamps circuit energy use architectural and display applications, but is one of
the least efficient lighting types available. These can
be replaced with high-efficiency halogens (30% more
efficient), CFL downlights or LEDs (80% more efficient)
for the same light output.
ACTION SAVINGS DETAIL COMPLETE?

Modernise 40 - 60% of light Due to a combination of age and design, most installed
fluorescent lighting circuit energy use fluorescent light systems (lamp, reflector and electrical
ballast) have room for substantial improvement in
efficiency. These aspects of the lighting system can
be improved by a professional redesign and refit with
high-efficiency T5 fluorescent fittings.

Replace high-bay 45 - 70% of light High-bay HID lighting - metal halide, mercury vapour
warehouse lighting circuit energy use and high pressure sodium – is commonly used in large
indoor areas such as warehouses and retail outlets.
Recent improvements in technology offer a range of
improved-efficiency replacement options, with the
most promising being T5 fluorescent high-bay light
fittings for most applications.

Investigate 20 - 60% of light Where skylights or large windows are present, indoor
daylight-based circuit energy use lighting is often still left on when natural light is
lighting control sufficient. Automated dimming or switching systems
can be used to reduce or eliminate the artificial lighting
load, and are also recommended for outdoor lighting
circuits.
LIGHTING

Install occupancy- 50 - 95% of light Lights left on in unoccupied areas like toilets and
based lighting circuit energy use storage rooms is a common occurrence. Ideally staff
control should turn lights off, but in practice the safest option
is often to install occupancy sensors to automatically
turn lights off in unoccupied rooms.

Install timers Up to 75% of light Leaving lights on in vacant buildings is a significant

on main lighting circuit energy use, energy wastage. Timers can be used to automatically
circuits depending on turn all lighting off during periods when normally
current practice vacant (e.g. night-time or weekends. A timed manual
override will allow staff to use the building outside
normal hours if necessary.
IT & OFFICE EQUIPMENT

Check management Up to $120 per PCs and laptops left on overnight can contribute
of PCs and laptops device per annum to major overall energy wastage. A simple out-of-
hours survey will identify which machines are left
on unnecessarily. Also, ensure 'power management'
is enabled to put machines into sleep mode
automatically when inactive (while most devices
typically switch the display off automatically, they will
continue to draw power unless specifically turned off
or put into sleep mode).

Check power Around $100 per Most modern photocopiers and printers come with
management device per annum inbuilt power management settings, but where these
of printers and have not been activated or older machines are used,
photocopiers the idle energy wastage can be large. Check that these
automatically enter 'power save' mode – and switch off
completely outside work hours.
MOTORS & DRIVE SYSTEMS

Install high- Up to 5% of motor New MEPS (Minimum Energy Performance Standard)

efficiency motors energy use motors are typically 2% - 3% more efficient than older
motors over a wide range of operating loads. MEPS
replacements are typically up to 5% more efficient for
rewound or lightly-loaded motors, and larger savings
are possible when replacing motors in poor condition.
ACTION SAVINGS DETAIL COMPLETE?

Replace standard Up to 5% of motor Standard V-belts have an efficiency of 93% - 98%

V-belts energy use depending on their age and tensioning. Cogged belts
are generally 2% more efficient than standard V-belts,
while synchronous belts typically have an efficiency of
98% and maintain this over their life.

Regularly service Up to 5% of motor Gearboxes contain oil to lubricate their gears and
gearboxes energy use reduce friction. Worn gearbox seals can leak oil,
increasing friction and lowering efficiency. Prolonged
operation with low oil levels can cause gearbox failure.

Bypass soft starter 3% of motor energy Motor soft starters typically have energy losses
units use equivalent to 3% of the motor’s power, dissipated as
heat. Once a motor is running at full speed, the loss
can be avoided by bypassing the soft starter using
external contactors. Many new soft starters already
have internal bypass contactors.
PUMPS

Consider pump Up to 50% of pump Over time, system changes may mean the originally-
replacement energy use specified pumps no longer run near best efficiency. A
pump’s maximum efficiency is often above 70%, but if
improperly specified, can be as low as 30%. Improving
pump efficiency can also reduce a pump’s rate of wear
and prolong its life.

Investigate variable Up to 80% of pump For varying loads, such as pressurising domestic
speed control on energy use water or circulating heating/cooling water, variable
pumps speed control of pumps can greatly reduce energy
consumption. A pump’s power consumption is
proportional to its speed cubed, so even small speed
reductions can result in large energy savings.

Trim pump Up to 20% of pump An oversized pump uses more energy than one
impellers energy use correctly sized. The pump may have always been
oversized, or the system’s flow requirements have
reduced since the pump’s installation. Trimming
a pump’s impeller reduces its capacity and hence
energy consumption. Ensure this is done in line with
manufacturers' guidance.

Isolate circulation 5% – 20% of pump Unnecessarily circulating water increases the pumping
loops when not energy use power consumption and in heating or cooling systems,
required increases the thermal load. When not needed,
circulation loops can be isolated either manually or
automatically, using solenoid valves. If the circulation
pump is controlled by VSD, isolating unneeded loops
gives even greater savings.

Install pressure Up to 90% of pump For pump systems with intermittent demand, pressure
switch control energy use switch control turns the pump off when not required
and eliminates the time the pump runs dead-headed.
This system can be used in conjunction with a pressure
accumulator, or bladder tank, to ensure the pump does
not cycle too frequently.

Install level control 5 - 75% of pump For dewatering or tank filling applications, pump
energy use level control ensures the pump only operates when
necessary. The level control may be a simple float
switch on a pump. More sophisticated methods include
using variable speed pumps that maintain a level by
matching inward and outward flows.
ACTION SAVINGS DETAIL COMPLETE?
FANS

Investigate variable 10 - 80% For varying loads, variable speed control of fans can
speed drives (VSD) greatly reduce their energy consumption. The fan’s
speed and output are varied using a VSD, and as a fan’s
power consumption is proportional to its speed cubed,
small speed reductions can result in large energy
savings.

Isolate circuits 5 - 20% Moving air unnecessarily can significantly increase

when not required the load on a fan. When not needed, air extraction
or supply ducts can be isolated by closing dampers,
either manually or automatically. If the fan is
controlled by VSD, reducing the fan system’s airflow
gives even greater saving.
STEAM GENERATION

Identify and repair Up to 30% of boiler Fixing steam leaks is often an easy, low- or no-cost way
steam leaks energy use of reducing your steam system’s operating costs and
increasing energy efficiency. Fixing leaks also helps
prevent damage to insulation on pipes and valves, and
reduces the system’s water and chemical use.

Test and repair 1 – 20% of boiler An effective steam trap selection and maintenance
steam traps energy use programme is essential to maintain the steam system’s
efficiency and performance. Replacing failed steam
traps often also reduces water and chemical use, for
additional savings.

Repair / upgrade / 1 - 20% of boiler All steam and condensate lines should be insulated
install insulation energy use to reduce heat loss and improve the quality of steam
reaching the end users. Steam valves and fittings are
often uninsulated, as solid cladding prevents easy
access to them. In these cases, removable thermal
jackets should be used to limit energy loss.

Maximise Up to 10% of boiler Recover condensate wherever economically practical.

condensate return energy use Steam that has delivered its energy by condensing still
contains approx 15% of its original energy. Returning
the condensate to the boiler feedwater tank reduces
the boiler load, resulting in energy savings. Additional
chemical and water savings often exceed the energy
cost savings from returning condensate.

Install economiser 5 - 10% of boiler Economisers increase energy efficiency by recovering

on boiler energy use heat from hot flue gases and using it to preheat boiler
feedwater. This effectively increases the boiler’s heat
transfer area. Possible savings vary, but efficiency
increases are typically 5% using a non-condensing
economiser and 10% using a condensing economiser.

Install automatic Up to 2% of boiler Boilers blow down (vent hot water) to control the
blowdown control energy use level of total dissolved solids (TDS). Excess TDS fouls
boilers and reduces efficiency. Manual blowdown
wastes energy if it is too frequent, or causes fouling if
too infrequent. Automatic controllers measure the TDS
level and blow down at the optimum rate.
ACTION SAVINGS DETAIL COMPLETE?

Install blowdown Up to 2% of boiler When a boiler blows down, valuable heat energy is lost.
heat recovery energy use Blowdown water is often above 150°C so is ideal for
heat recovery. Most boiler blowdown heat-recovery
applications preheat boiler feedwater, although
offsetting other heat loads may be possible. The savings
achievable depend on the boiler’s blowdown rate.

Conduct regular 2 - 10% of boiler Periodic testing of a boiler’s efficiency, by measuring

boiler combustion energy use excess air levels and exhaust temperatures, is essential
efficiency testing to ensure optimum operation. Too high an excess air
level lowers efficiency and indicates burner adjustment
is required, while too high an exhaust temperature
indicates the boiler tubes are fouled and need cleaning.

Install automatic Up to 3% of boiler On boilers with large burners, oxygen trim sensors
air-fuel controls energy use can automatically adjust the burner’s air-fuel ratio for
maximum efficiency. By adjusting the boiler so the
excess oxygen level is optimum, the minimum amount
of excess air goes through the boiler.
STEAM GENERATION

Clean boiler at Up to 10% of boiler Boiler tubes are fouled on the fire-side by soot from
regular intervals energy use burning fuel, and on the water-side by deposits from
feedwater impurities. Fouling decreases the heat
transfer from the combustion gasses to the water,
increasing the exhaust temperature and reducing
efficiency. Regular fire-and water-side cleaning
ensures good heat transfer is maintained.

Reduce boiler 1 - 2% of boiler Steam boilers are often set to produce steam at about
pressure setpoint energy use 9 bar.g, even though the steam accumulator typically
stores steam at a lower pressure (about 3 - 4 bar.g),
for use in the moulding machines at an even lower
pressure (often 2 - 3.5 bar.g). Reducing the steam
pressure to about 6 bar.g will slightly improve boiler
efficiency, but check with your boiler contractor to
make sure this change is properly monitored.

Install flue gas 2 - 10% of boiler For a hot non-firing boiler, natural convection can
isolation dampers energy use cause air to flow through the boiler and out of the flue,
removing heat from the system. A flue-gas isolation
damper that closes when the boiler is not firing
reduces natural convection heat losses, lowering the
standby losses.

Consider more 10 - 20% of boiler Modern moulding machines have more automation to
automation for energy use more tightly control steam consumption during the
moulders to reduce moulding process. For example, pressure feedback
steam consumption can limit the amount of steam used instead of a timer-
controlled valve. Discuss with the moulding machine
manufacturer, or a specialist machinery contractor, or
consider a new moulding machine.
COMPRESSED AIR

Identify and repair 20 – 50% of Compressed air leaks commonly account for 20% to
compressed air compressed air 50% of total compressed air consumption. Air leaks
leaks energy use are costly because they consume compressed air
continuously, even if no production is occurring. Fixing
leaks is often as simple as tightening a loose connector,
and as a result can provide an extremely attractive
payback period.
ACTION SAVINGS DETAIL COMPLETE?

Identify and remedy 5 – 50% of Compressed air systems are only about 12.5%
compressed air compressed air efficient, with each unit of work requiring eight units
misuses energy use of electricity. Unregulated, unnecessary use of air
can almost always be replaced with more efficient
technologies. Remedying misuse saves energy and
can delay the need to purchase additional compressor
capacity.

Reduce compressor Up to 14% of Compressed air devices are often designed to operate
pressure setpoint compressed air at 6.0 bar, though many sites supply air at 7.0 bar.
energy use Assess the site’s air pressure requirements; if no
devices need air above 6.0 bar, then reduce the air
pressure setpoint. A 1.0 bar pressure reduction reduces
energy use by 7%.

Reduce distribution Up to 14% of Excessive pressure drops can result from installing too
pressure drop compressed air much equipment on an undersized compressed air line.
energy use To get enough pressure at the machines, the system
pressure is then increased, which lowers efficiency.
Increasing the line size reduces pressure losses,
maintains efficiency, and results in a more stable
pressure.
COMPRESSED AIR

Improve capacity 5 – 30% of Air compressors with good turn-down efficiency,

control compressed air such as a variable speed or variable displacement
energy use compressors, can use up to 30% less energy than other
capacity control methods.

Improve intake 2 - 10% of Poor air quality, high air temperatures and low inlet
design compressed air pressures reduce an air compressor’s efficiency.
energy use Ensure there are no inlet restrictions - e.g. blocked
filters - and that the compressor receives clean, cool
air. A 3°C reduction in air temperature will typically
reduce compressor energy consumption by 1%.

Install heat 50% of compressed More than 60% of an air compressor’s input energy
recovery air energy use is lost as heat. The heat of compression can be used
directly for space heating or indirectly for heating
water, for domestic use or as boiler feedwater. Many
compressor manufacturers sell kits to recover the
waste heat for water heating.

Improve sequencing 0 - 20% of Advanced control systems can monitor a plant's

controls compressed air pressure and flow requirements, allowing optimum
energy use control of installations with multiple air compressors.
The control system reduces the time air compressors
run unloaded, can eliminate over-pressurisation during
times of low demand and will improve the system
pressure stability.

NOTES