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Optimize Energy Across Your Factory And Be More Energy Efficient

Energy shortages means higher prices for gas and electricity, which is driving up operational costs for manufacturers. The big question on most manufacturer’s lips is how to make manufacturing operations more energy efficient?
Written by
Published on
January 3, 2023

The current energy crisis is causing a major headache for manufacturers.

Energy shortages means higher prices for gas and electricity, which is driving up operational costs for manufacturers. 

It could be described as a Catch-22 situation – manufacturers are looking to diversify their offerings and increase productivity due to the global economic crisis, but rising energy costs are making it unprofitable to increase throughput.

The big question on most manufacturer’s lips is how to make manufacturing operations more energy efficient.

In this article, we’ll list 4 key ways to increase energy efficiency, while simultaneously increasing productivity and innovation.

1. Replace or Upgrade Old Equipment

Replacing old equipment with new technologies is one of the best ways to optimize your facility’s energy efficiency. Many older machines are not designed with energy conservation in mind, so replacing them with modern machines that use less electricity can dramatically reduce your overall energy costs. For example, investing in newer electric motors may require a larger initial investment but is likely to pay off over time due to their improved efficiency. 

2. Install Automation Systems 

Another strategy for improving efficiency is to install automation systems throughout your facility. Automated systems can minimize manual labor and reduce waste, resulting in increased operational efficiency and cost savings. By automating processes such as material handling, quality control testing, or inventory management, you can maximize productivity and minimize energy consumption. 

Additionally, these automated systems often include built-in sensors that monitor machine performance and alert operators when issues arise—reducing downtime and further improving your bottom line.  

3. Implement Smart Manufacturing Solutions

Smart manufacturing technology goes beyond traditional energy efficiency solutions by incorporating smart devices, such as smart thermometers and smart energy meters. Smart manufacturing devices, when connected to a platform like O3, allow factory managers to monitor energy levels in real-time, detect excessive energy usage quickly, and generate data insights on how to conserve energy. 

Smart manufacturing technology reduces the amount of energy wasted in a variety of ways:

  • Detecting equipment that doesn't need to be running 
  • Highlighting processes that use more energy than necessary 
  • Track the cost of energy use and identify areas for optimization and improvement.
We've made it easier than ever to learn about O3 for Energy Optimization and get started. Visit the O3 solution site and check out our video to see why we're the best choice to boost energy efficiency and utilization.

4. Use Energy Management Software

Installing an energy management software system is another great way to make sure you're using the least amount of energy possible without sacrificing productivity or quality control. 

In fact, when you combine AI-driven energy management software with smart manufacturing technology, you can monitor and control all aspects of production from start to finish – from raw materials entering the facility to finished goods leaving it. You can ensure that every process is running with optimal energy efficiency. 

For example, if you fit out your production line with IoT sensors and O3’s data capture and analysis modules, you can monitor electricity use and energy waste. You can also apply  predictive analytics capabilities that anticipate problems before they occur, saving valuable time and money while reducing your carbon footprint at the same time.

Key Takeaways

There are four main ways to rapidly improve energy efficiency and cut costs, without negatively impacting productivity: replace or upgrade outdated equipment with new technologies, install automation systems throughout your facility, implement smart manufacturing devices, and use an energy management software system.

The cost of implementing these upgrades are likely to be offset by the energy savings in a short space of time. You will also boost your eco-credentials by becoming a more sustainable manufacturer.

At O3, we not only provide the technology and software you need to become more energy efficient, but we also provide assistance every step of the way. We have a team of smart manufacturing specialists and value engineering experts on hand to identify key supply chain and production areas for improvement and help you to implement the right solutions for your business.

Get in touch today to book a discovery call.

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