How continuous energy management can help you realize this potential

The aim of an energy management system is to reduce and continuously optimize energy consumption in the company. Energy costs represent a high proportion of total production costs, particularly in manufacturing companies. It is precisely here that potential savings in energy consumption and therefore also potential cost savings can be identified through continuous energy management. In the following article, we would like to share our experiences with our customers in the manufacturing SME sector and highlight the five typical savings potentials that we regularly observe in manufacturing companies.

1. Unnoticed standby loads

We've all been there: you switch off the TV at home and the red standby light is on. At this moment, the TV continues to draw power and costs you a lot of money over the year. We also observe the same scenario in industry, except that the "industrial TV" costs you significantly more money than the home TV. When operation is at a standstill, unnoticed standby loads can be easily identified and subsequently avoided by measuring the transfer meter. If unusually high standby loads are identified by a measurement, the cause must be identified in the next step and reduced by switching off or a suitable countermeasure. This reduces electricity consumption and lowers energy costs.

Standby loads can be detected immediately by evaluating the load profile on the transfer meter.

2. Avoidable peak loads

For industrial companies that draw more than 100,000 kWh of electricity per year, the power (kW) is usually measured in addition to the energy quantity (kWh) and billed by the grid operator. This takes into account the increased load on the supply grid above a certain power consumption. In a normal tariff, payment for the power is based on the annual peak load , the highest 15-minute load that has occurred in a year. This annual load peak is therefore determined by the actual demand curve and the averaging of this curve in a 15-minute time window. With the help of high-resolution data (15-second intervals), such power curves can be precisely analyzed and insights into load management can be derived. This can, for example, lead to switch-on schedules for machines and systems in order to prevent an increase in peak loads and thus save on electricity bills.

3. Reduced transformer losses

Transformers are often operated inefficiently and lead to energy losses during voltage conversion. These losses can be caused, for example, by outdated technology, poor design, operation at an inefficient operating point or other faults. The efficiency of transformers can be easily checked by measuring the transformer downstream. This involves comparing the measured data at the upstream transfer meter (RLM meter) and the downstream measuring points. This comparison is particularly interesting at times away from regular operation (e.g. at weekends). If there are significant inefficiencies, these can be identified immediately and potential savings can be realized promptly.

4. System overloads due to harmonics

Harmonics represent a "pollution" of the grid and are harmful to devices, machines and highly relevant for operational safety. They can bring production lines and IT systems to a standstill and even lead to cable fires. One way to avoid such operational uncertainties caused by "harmonics" is to measure the high-frequency currents in the company network. This enables the identification and causes and the targeted derivation of measures to prevent harmonics.

5. Avoidable downtimes

By continuously measuring the energy consumption of individual machines and systems, for example, anomalies in consumption that indicate a defective machine can be detected. The measured consumption is compared with historical data to identify unforeseen consumption. Linking energy data with basic data from production, such as the number of units produced, also allows conclusions to be drawn about anomaliesby calculating key figures and comparing them with historical data. If, contrary to expectations, more energy per unit is consumed in production, it is worth taking a closer look at the machine in order to anticipate and avoid possible production losses and downtimes at an early stage.

Energy saving potential Anomaly detection

Practical experience shows that energy saving potential lies dormant in most manufacturing companies and can be realized most reliably with the help of continuous measurement of electrotechnical parameters. On average, our customers save 8% of their energy costs with the help of the ENIT Agent. The continuous recording of high-resolution energy data is therefore the essential foundation for potential savings. Detailed examples of possible cost savings can be found here: