Industrial energy efficiency resources for state & utility programs

States and utilities can use the tools and resources below to help get an understanding of energy use in the industrial sectors located in their area, and how to work with manufacturers to improve energy efficiency, develop stronger energy efficiency programs, and promote industrial energy performance improvement. Through ENERGY STAR, the US EPA has worked in the industrial sector for over a decade and has produced a library of industrial energy resources. A table summarizing ENERGY STAR resources by industrial sector is provided below.

See the ENERGY STAR Industrial Insights below for an overview of energy use and greenhouse gas emissions in selected industrial sectors.

Save 2-10 percent annually

Industrial plants can be large consumers of electricity. Through ENERGY STAR, US EPA has seen that most industrial facilities can improve their total energy performance 2-10 percent annually. Much of these savings can come from improvements in electrical efficiency, although specific improvement potentials will vary by sector and plant.

Identify and estimate potential savings in the industrial sector

Begin by evaluating the types of manufacturing plants within your territory. Utilities servicing industrial customers will have load profiles and historical energy use data on industrial plants regardless of whether those plants have participated in industrial efficiency programs or not. State permitting agencies also can be used to identify industrial plants by their NAICS code.

How much improvement a plant can make depends on many factors. One method for evaluating this is through use of ENERGY STAR sector-specific benchmarking tools, known as ENERGY STAR Plant Energy Performance Indicators (EPIs). These can be used to evaluate the performance of individual plants and the range of energy performance within in a given industrial sector. For instance, a state could use the EPI to calculate how far from the industry average a particular cement plant is for its energy. This information would be a step in helping to inform the level of effort that would be required to improve this plant’s energy efficiency.

For more information, see: Plant Energy Performance Indicators.

Through ENERGY STAR, US EPA has developed a series of Energy Guides that discuss both process and non-process electric efficiency opportunities for over 16 industrial sectors. These guides can be used to assess potential opportunities for electrical efficiency. The guides also report on how to improve on-site fuel use.

For more information, see: Sector Energy Guides

Opportunities for electrical efficiency

Industrial electrical energy use is distinguished between process and non-process energy uses. Non-process electric loads are the most common improvements in industrial plants. Upgrades and optimization strategies are well established, and savings can be easily measured and verified. Common non-process electrical loads and use include:

• Chiller and refrigeration systems
• Compressed air systems
• Motors and drives
• Ventilation and fans systems
• Packaging systems
• Lighting
• Monitoring and control systems

While some state and utility programs have offered incentives and rebates focused on these systems, US EPA still sees many plants pursuing these measures for savings.

An individual plant can be helped to improve energy efficiency by evaluating its opportunities for process electrical efficiency. Because of the customized nature of process-related equipment, it will be necessary to work closely with manufacturing plants to identify, quantify, and incentivize improvements.

Process-related electrical energy uses are specific to individual industrial sectors and require customized upgrades and optimization solutions. Significant savings can come from process improvements. Examples of process electric loads include:

• Packing systems
• Machining equipment
• Injection molding equipment
• Painting and coating booths
• Stamping and metal forming presses
• Electric arc furnaces

Energy management guidance

Companies that establish energy programs generally achieve greater efficiency improvements and sustain those improvements over time. ENERGY STAR offers a variety of resource to assist companies and industrial plants in forming effective energy management programs. Key resources include:

• ENERGY STAR Guidelines for Energy Management - Guidance for establishing an energy management system and program.
• Teaming up to Save Energy – Instructions on forming site and corporate energy teams.
• Energy Treasure Hunts – Guidance for how to effectively identifying low cost, operational, maintenance, and behavior-oriented efficiency opportunities.

Additional tools are located at www.energystar.gov/industry. To further discuss industry within your area, contact energystrategy@energystar.gov.

Industrial insights

These two-page documents provide an overview of how energy is used in sectors working with ENERGY STAR.

• Auto assembly plants
• Cement manufacturing plants
• Pharmaceutical manufacturing plants
• Wet Corn Mills

EPA will be adding additional insights over the coming months.

ENERGY STAR resources by sector