6 Reasons for energy management in industrial SMEs

Why energy management pays off in SMEs

 

In Germany, industrial and commercial enterprises account for a good 40% of the country’s total energy consumption. Sigmar Gabriel describes the energy efficiency in the industrial middle class as the „sleeping giant of the energy turnaround“. More than 90% of the manufacturing companies in Germany make up the industrial middle class. In our blog contribution we would like to give you 6 reasons why energy management is important in the industrial middle class and which potentials can be uncovered thereby. An energy management system makes the systematic collection of all consumptions possible within an enterprise. On the basis of the data collected, it is possible to carry out a more in-depth analysis of electricity consumption. Depending on the system, this makes it possible to analyze the power consumption per workpiece or the emergence of a peak load. New sophisticated analysis algorithms will also make it possible in the future to minimize downtimes by detecting faults or wear at an early stage. The analysis of deviations in the energy data provides the basis for early detection of possible machine failures due to defects or wear. But why should a medium-sized company buy an energy management system?

Trafoverluste
With the help of a Sankey diagram, energy flows can be visualized within the company in real time.

1. Cost savings

The new transparency through the collected data offers the possibility to detect unrecognized consumers. Experience with our customers shows that the typical savings potential lies in reduced transformer losses, unnoticed standby loads and avoidable load peaks. The typical energy cost savings potential after the introduction of an energy management system is 5%-20%. The lower cost level thus also increases the competitiveness of an industrial company.

2. Increase in productivity

Per definition, productivity in production increases when the output quantity increases in relation to the input quantity. The result is that more is produced with the same use of resources. An energy management system offers the possibility to measure the amount of energy that flows into the production and thus to uncover weak points that lead to unnecessary additional consumption. Our experience in medium-sized businesses shows the following typical weak points that stand in the way of efficient production:

  • Equipment that exceeds demand and operating times
  • Missing controlling of energy costs
  • Not recognized maintenance requirements

3. Saving resources

The saving of resources is one of the direct consequences of reduced and more efficient energy consumption. This is not only reflected in the company’s electricity bill, but also benefits the environment.

4. Facilitating energy audits through continuous energy management

In the context of the energy turnaround that has been adopted, energy audits at companies are gaining in importance for the legislator. Even if small and medium-sized enterprises are excluded from the obligation to carry out an energy audit, the energy audit is the prerequisite for tax advantages. An existing energy management system significantly simplifies the performance of energy audits. The energy audit provides for the recording of energy data as preparation for the on-site inspection by the energy auditor. By implementing an energy management system, the relevant data for the audit is already available and can be made available to the auditor in an uncomplicated manner.

Tabelle Energieaudit

The simple and clear visualization of energy data is one of the advantages of an energy management system.

5. Troubleshooting critical operating states

An energy management system can be used to monitor operating states via the recorded power consumption. If it is necessary that certain systems, such as pumps, are permanently in operation and a failure is to be avoided, the energy management system helps to ensure this. In addition, the power quality can control the supply quality of the power supplier and possible problems in the voltage quality, such as harmonics, can be detected. In addition, the risk of fire can be reduced by monitoring the N conductor currents.

kritische Betriebszustände

On the basis of historical consumption data, deviations can be detected and errors detected.

 

6. Higher data accuracy

Thanks to the continuous recording of energy data in high resolution, it is possible to carry out a more detailed analysis than with selective manual recording. The availability of high-resolution data over a longer period of time makes it possible to learn from historical consumption and to derive targeted measures. For example, it is possible to determine the optimum maintenance time for a machine on the basis of historical data and thus minimize potential downtimes in production.

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