Manufacturing Plants: An Overview of Energy
Use and Energy Efficiency Opportunities
Energy Use in Manufacturing Plants
Manufacturing operations are among the most energy-intensive in the U.S. Whether making steel, refining oil, or canning
vegetables, there is great potential for improving energy efficiency.
Manufacturers produce heat and operate machinery using a variety of energy types, ranging from conventional sources such as
electricity and natural gas to non-conventional fuels including shredded tires and black liquor. Industrial energy use is responsible
for almost 30 percent of all U.S. greenhouse gas emissions, which contribute to global climate change.
Energy Efficiency Opportunities
Manufacturers of all sizes can take several simple steps to manage energy.
> Measure and track energy performance. Key steps include benchmarking plant energy use with
ENERGY STAR or other benchmarking approaches when available and setting an energy savings
goal.
> Improve common plant systems such as motors, compressed air, steam, process heating, etc.
Evaluate systems for waste and misuse, operate them as designed, eliminate leaks, increase
insulation where appropriate, and design systems for plant needs, adjusting them as needs
change.
> Turn off what is not required. Key steps include walking through the plant when not in operation
to identify energy waste, checking hours of operation and settings on equipment, establishing a
list of energy shut-down procedures, reviewing these with plant managers and employees, and
periodically inspecting plant adherence to procedures.
> Get employees involved. Hold staff meetings on energy use, costs, objectives, and employee
responsibilities; procure ENERGY STAR products and other energy-efficient equipment where
available.
> Check the lights. Replace old fluorescent and incandescent lighting with T-8s, ENERGY STAR
qualified compact fluorescent light bulbs (CFLs) and other energy-efficient lighting systems, and
implement a regular lighting maintenance program. Turn lights off when not in use. Maximize task
lighting, daylight, and use of occupancy sensors.
Manufacturers Making a Difference:
California Portland Cement Company, CA,
used the ENERGY STAR Guidelines for
Energy Management to start its
corporate energy management program
in 2003. Cal Portland invested in
employee energy education, plant
benchmarking, and energy-efficient
technologies to achieve significant
energy savings.
Merck & Co., Inc., NJ, reduced energy
use by 9.4 percent in 2006 due to its
structured corporate energy program.
Based on aggressive initiatives to
increase accountability for energy use,
educate employees, and upgrade
facilities, Merck's leadership is making
progress toward a company-wide goal of
reducing energy use by 25 percent by
2008.
How to Talk to Manufacturers About Energy Efficiency
Manufacturers should recognize that energy is a controllable operating expense and that energy
should be managed with the same expertise as other parts of the business.
Start by focusing on whether there is someone who is accountable for energy consumption in the
company. From there, build on the discussion by introducing the ENERGY STAR Energy Program
Assessment Matrix. This tool is ideal for beginning a dialogue about the elements of comprehensive
energy management.
Other Resources for Manufacturers:
The Department of Energy's Industrial
Technologies Program
(www1.eere.energy.gov/industry): This
program offers help to manufacturers in
the form of energy-efficient technologies,
plant energy assessments, and resources
for addressing energy consumption in
plant systems.
ENERGY STARŪ is a government-backed program helping businesses
and individuals protect the environment through superior energy efficiency.
LEARN MORE AT
energystar.gov
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Manufacturing Plants: An Overview of Energy
Use and Energy Efficiency Opportunities
ENERGY STAR Resources
Guidelines for Energy Management: Based on the successful practices of ENERGY STAR partners, these
guidelines can assist manufacturers in improving their energy performance while establishing themselves
as environmental leaders.
Plant Energy Performance Indicators (EPIs): EPIs are available for select plant types. EPIs enable
benchmarking of energy consumption on a national basis for particular industries and may be downloaded
from "Industries in Focus".
www.energystar.gov/epis
Energy Management Assessment Matrices: Strong energy management practices save energy. The
ENERGY STAR Energy Program and Facility Energy Management Assessment Matrices help companies,
energy managers, and others evaluate their energy management practices in comparison to the best
practices outlined in the Guidelines. These tools also help identify opportunities for improvement.
www.energystar.gov/in(lex.cfm?c=giii(lelines.assess facility energy
Recognition for Achievements
Earn the ENERGY STAR: Plants that rate in the top 25 percent of energy-efficient plants in their industry
using an ENERGY STAR EPI may qualify for the ENERGY STAR.
www.energystar.gov/plants
Become an ENERGY STAR Leader: ENERGY STAR Partners who demonstrate continuous improvement
system-wide may qualify for recognition as ENERGY STAR Leaders. EPA will recognize systems that have
achieved reductions of 10,20,30 percent, or more. To learn more, visitwww.energystar.gov/leaders.
Visitwww.energystar.gov/industryformore information on ENERGY STAR resources.
ENERGY STAR Offers:
- Guides
- Corporate and plant
energy program assessment
matrices
- Plant benchmarking
- Networking/training
- Technical support
- Motivational campaigns
- Recognition
ENERGY STARŪ is a government-backed program helping businesses
and individuals protect the environment through superior energy efficiency.
LEARN MORE AT
energystar.gov
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