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Measures That Can Be Applied for Energy Conservation in Manufacturing Facilities

Although the importance of energy efficiency in production facilities is always considered, we often see that savings opportunities are overlooked in some cases. It is extremely easy to make significant gains by saving energy with an accurate energy monitoring system and big data analysis. Although the distribution of energy consumption of different production companies varies according to the sector. We have summarized some points that may be valid in all sectors with the data obtained from thousands of viewpoints as follows:

• Verification of energy bills
  From time to time, erroneous invoices may occur due to meter failure or other technical problems. Finding a reference system to verify the invoice will be effective in preventing high invoices by providing instant detection of such cases.


• Controlling reactive energy consumption and compensation
  If the reactive energy consumption rate exceeds the limits in the relevant regulation, a reactive consumption penalty is imposed. If compensation is not applied correctly, these amounts can reach quite high figures. Real-time monitoring of reactive consumption is very important even if the compensation system is installed. Additionally, in cases such as sticking of the contactor of the compensation panel or failure of the capacitors and addition of new equipment to the system can change the reactive consumption characteristics of the relevant facility. This can result in reactive penalties.


• Measurement and analysis of consumption separately for air conditioning, lighting, production machines
  Although measuring the total energy consumption of the facility is important in terms of providing a general control and control of the reactive consumption, it is very difficult to find concrete savings points without monitoring the consumption of each sub-unit. For example, it is extremely difficult to determine if the lighting is left on during the day by simply monitoring the total consumption. For this reason, the energy consumed for lighting, air conditioning and production must be measured separately. In fact, line-based and machine-based monitoring will be extremely useful for production. By monitoring in this manner, it will be extremely easy to detect the problem, for example, a machine that draws 300-400 Amperes under normal conditions can easily reach 500 Amperes due to malfunction or lack of maintenance, and so, by preventing excess consumption and applying the necessary maintenance to the machine, loss in production can be prevented.


• Selection of the most suitable electricity tariff by extracting the load profile
  Monitoring the load profile for a few months will lead to savings by choosing the most accurate tariff for the facility. Sharing load profiles with energy distribution companies can also enable companies to submit special price offers.


• Determining standby consumption and keeping them down while the machines are idle
  Many machines consume a large amount of energy while on standby. It is not possible to keep these machines off only with administrative measures and individual initiatives, and this is reflected in the energy bills. With the low-cost and highly efficient Lite Analyzer developed by Trio Mobil, the load profiles and the standby status of the machines can be determined and excessive standby periods can be prevented. At the same time, if the current levels of the machine increase abnormally during production, a notification is received, preventing excessive consumption. Additionally, malfunctions that will cause production interruptions are also detected before they occur.


• Monitoring the consumption of air conditioning (heater - cooler) systems and ensuring that they remain closed out of working hours
  Air conditioning systems have an important share in the energy consumption of facilities. Depending on the structure of the facility and seasonal conditions, its share in consumption can reach up to 30-40%. Usage-based energy losses are very common even if a system with high energy efficiency is used. The most common energy losses are leaving the systems open outside of working hours, entering hot or cold set values into the systems unnecessarily, or keeping the air conditioning systems open even though there is nobody working in the environment. By monitoring the energy consumption of the air conditioning system, you can receive instant notifications if the consumption is above the determined levels outside of working hours. With the visual reporting tools provided by Trio Mobil, it is possible to analyze such savings opportunities in a short time.


• Ensuring that the lighting systems remain off when there is daylight
  The use of LED technology in lighting systems is an important requirement in terms of energy efficiency. However, whichever lighting technology is used, it is very important for energy saving to turn the lighting on and off in accordance with the operating rules. Leaving the lighting on during daylight, not turning it off during breaks although there are no employees, causes energy loss. With the Trio Mobil alarm and rule management module, unnecessary usage can be easily detected by determining time-based consumption limits.


• Performing regular maintenance, monitoring the efficiency of the motor and pump, and making the necessary arrangements
  Even if the motors and pumps working continuously in many factories have low power, they cause high energy consumption because they work continuously. It is extremely important to measure the energy consumption of electric motors and pumps separately, both in terms of determining the consumption of different brands and models in real use apart from the catalog data, and in order to quickly determine the high consumption due to lack of maintenance or malfunction.


• Preventing the doors of cold storages from being open for a long time
  The use of cold storages is very common in facilities producing food, medicine and chemicals. The share of these systems operating 7-24 in energy consumption can be extremely high. With the Trio Mobil IoT Platform, energy consumption, temperature values and door status of cold storage can be monitored digitally. By monitoring the open/close state of the door, it is made possible to save unnecessary energy consumption that will arise during loading/unloading operations where the system will consume high level of energy trying to keep the determined temperature each time the door is left open more than necessary.


• Installation of solar panels to produce energy from solar energy
  Solar panels, which have increased efficiency and decreased costs with the developing technology in recent years, constitute both a low-cost and zero-emission energy source for industrial establishments. Considering that the return on investment is between 4-6 years depending on the region where the facility is located, it is seen that such an investment will be extremely well-directed. The measurement systems integrated into the Trio Mobil IoT Platform allow you to control and analyze energy production as well as consumption.