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Energy Management for Small and Medium Sized Manufacturers

factory worker
DeBourgh manufacturing, locker welding

Finding energy savings starts by making energy management a priority.

Sustaining those savings and driving further reductions requires building energy management into your company’s culture.

ENERGY STAR can help you get started regardless of the size of your company.

Our small and medium manufacturer (SMM) resources are designed to help you:

Begin Finding Energy Savings


Is capital tight? Better operating practices and equipment tune-ups help many manufacturers achieve significant energy savings – at little cost.

Start saving now. Read our easy-to-use guide to identify energy saving opportunities that can be made in your plant.

Managing Your Energy guide thumbnail

Managing Your Energy: An ENERGY STAR Guide for Identifying Energy Savings in Manufacturing Plants pdf (407KB)

Need some quick tips? Use our animated tour of energy savings in a manufacturing plant. Share this with your employees to get them thinking about energy savings, too!

launch interactive plant

Tour a manufacturing plant and find ways
to save energy by clicking on the icon above!

Get started on finding savings. Use the checklists below to begin to identify energy savings in your plant.


Lighting

Lighting is a significant energy use and cost for most manufacturers, and an area with many opportunities for savings.

Lighting Focus Area Action Items
checkmark Are unoccupied areas lit? See Section 4.1 in Managing Your Energy: An ENERGY STAR Guide for Identifying Energy Savings in Manufacturing Plants pdf
checkmark Are lights left on during non-work hours?
checkmark Are parts of the facility over-lit?
checkmark Is older, inefficient technology in use?
checkmark Are exit lights using old technology?
checkmark Can daylighting be used?


Heating, Ventilation and Air Condition (HVAC) Systems

HVAC systems can be a significant energy load for small manufacturing plants. It is important to keep these systems operating efficiently.

HVAC Focus Area Action Items
checkmark Are temperature set points turned back during non-production hours? See Section 4.2 in Managing Your Energy: An ENERGY STAR Guide for Identifying Energy Savings in Manufacturing Plants pdf
checkmark Are temperature set points at the right level?
checkmark Is duct work leaking?
checkmark Is the building well insulated?
checkmark Are HVAC systems programmed correctly and operating according to manufacturer’s instructions?
checkmark Are coils cleaned regularly?
checkmark Are air filters changed appropriately and regularly?
checkmark Is older, inefficient technology being used?


Motor Systems

Motors, widely used in manufacturing, are found in process equipment, HVAC systems, air compressors, and other systems.

Motor Focus Area Action Items
checkmark Are motors properly sized? See Section 4.3 in Managing Your Energy: An ENERGY STAR Guide for Identifying Energy Savings in Manufacturing Plants pdf
checkmark Are motors maintained?
checkmark Can adjustable or variable speed drives be installed?
checkmark Can older, less efficient motors be replaced?
checkmark Do you have a motor management program?


Compressed Air

Did you know that compressed air is the most expensive plant utility? Make sure you're not wasting air!

Compressed Air Focus Areas Action Items
checkmark Are hoses and lines regularly checked and repaired for leaks? See Section 4.4 in Managing Your Energy: An ENERGY STAR Guide for Identifying Energy Savings in Manufacturing Plants pdf
checkmark Is the system properly maintained?
checkmark Is compressed air used only for critical uses?
checkmark Is the system over-pressurized or over-sized?
checkmark Can pressure be stabilized or reduced?
checkmark Are too many air compressors running to meet the load?
checkmark Is compressor performance monitored regularly?


Steam Systems

Assessments of industrial steam systems find, on average, 10% to 15% annual energy savings.

Steam System Focus Areas Action Items
checkmark Are controls in use to monitor oxygen levels, flue gas leaks, and air intake? See Section 4.6 in Managing Your Energy: An ENERGY STAR Guide for Identifying Energy Savings in Manufacturing Plants pdf
checkmark Are the boiler and distribution system properly sized?
checkmark Are distribution systems properly insulated?
checkmark Are steam traps regularly checked for failure and replaced?
checkmark Is steam condensate re-used?
checkmark Is heat recovered from flue gas to preheat boiler feed water?
checkmark Are older, less efficient boilers in use?


Manufacturing Processes

Improving operating practices for energy efficiency is an excellent source of no-cost savings opportunities.

Steam System Focus Areas Action Items
checkmark Can idling equipment, machines or systems be turned off? See Section 4.1 – 4.8 in Managing Your Energy: An ENERGY STAR Guide for Identifying Energy Savings in Manufacturing Plants pdf
checkmark Can startup and shutdown times for equipment, machines or systems be reduced?
checkmark Are systems and machinery properly commissioned?
checkmark Are systems optimized for production?

Free Software Evaluation Tools

Want to evaluate your systems further? The Department of Energy (DOE) offers free software tools to help you evaluate motor, fan, steam and other systems to identify energy savings opportunities.

Visit DOE’s Industrial Facility Tool Suite.

Office Equipment

Take advantage of ENERGY STAR qualified products to help you reduce your energy use. Office equipment, water coolers, computers, vending machines and more all help to reduce the energy load.

How to Pay for Upgrades to Plant Systems and Equipment


Upgrades and improvements to plant systems and equipment will likely require capital. The good news is these projects often have short payback periods, increase plant productivity, and are generally low risk investments with guaranteed returns.

Some states and utilities offer rebates and financial incentives that offset equipment costs. Current federal tax incentives can also bring down the cost of equipment upgrades. Read more about these resources and assistance programs to offset costs.