Running a small manufacturing facility or workshop comes with many challenges, not least of which is managing electricity costs. With rising energy prices, business owners are searching for ways to save money without compromising productivity. Fortunately, implementing the right strategies can help. In this guide, we’ll share practical energy saving tips for businesses, tailored for small manufacturing operations, that can cut electricity bills while often improving overall efficiency.
Why Energy Efficiency Matters for Small Businesses
Energy efficiency is not just about lowering utility bills—it’s also about gaining a competitive edge. For small manufacturers, even modest reductions in energy consumption can lead to significant savings over time. By focusing on energy efficiency, you’re also extending the lifespan of equipment, improving workplace comfort, and contributing to sustainability goals that are increasingly important to customers.
The following energy saving tips for businesses will help you identify practical steps that are both cost-effective and relatively easy to implement.
Energy Saving Tips for Businesses: Key Strategies for Small Manufacturing Facilities
1. Upgrade to High-Efficiency Motors and Variable Frequency Drives (VFDs)
One of the best energy saving tips for businesses in manufacturing is to upgrade old motors to modern, high-efficiency models. Motors are often the largest consumers of electricity in workshops, powering machinery, fans, and pumps. Switching to energy-efficient motors can reduce consumption significantly.
Adding Variable Frequency Drives (VFDs) to motor-driven systems is another powerful step. VFDs adjust motor speed to match demand, which prevents wasted energy when full speed isn’t needed. For instance, in HVAC systems, VFDs reduce energy by controlling fan speeds based on occupancy or temperature needs.
Action Point: Conduct an assessment of your facility’s motors and prioritize upgrades where possible. While upfront costs exist, payback periods are often short thanks to the consistent savings.
2. Use Occupancy Sensors for Lights and Equipment
Lighting and idle equipment are silent contributors to energy waste. Installing occupancy sensors ensures lights and non-essential equipment are switched off when no one is around. This is especially useful in storage rooms, restrooms, break areas, and workshop corners where lights are often forgotten.
For workshops, motion detectors can also be applied to ventilation fans and other auxiliary equipment. By automating these systems, you’ll eliminate human error and improve efficiency.
Action Point: Identify low-traffic zones in your facility and install occupancy sensors to automate energy savings.
3. Improve Insulation and Seal Air Leaks
Heating and cooling costs often represent a significant portion of a business’s electricity bills. Poorly insulated facilities lose heat in winter and cool air in summer, forcing HVAC systems to work harder. Small workshops can benefit from sealing cracks in doors and windows, insulating walls, and adding thermal barriers to roofs.
Don’t overlook equipment insulation either. Boilers, ovens, and heated tanks can be insulated to prevent heat loss. This not only saves energy but also improves worker safety by reducing surface temperatures.
Action Point: Schedule a facility walk-through to check for drafts and heat leaks. Investing in insulation and weatherproofing can bring rapid returns.
4. Perform Regular Energy Audits
Energy audits are a cornerstone of effective efficiency strategies. A thorough audit identifies where and how your facility is using (and wasting) energy. This may involve reviewing utility bills, analyzing equipment performance, and using tools like infrared thermometers to detect inefficiencies.
Small businesses can start with a self-audit by checking for obvious waste (e.g., machines running idle, compressed air leaks). For deeper insights, consider hiring a professional energy auditor who can recommend customized improvements.
Action Point: Establish a yearly energy audit schedule and track progress over time.
5. Optimize Compressed Air Systems
Compressed air is often called the "fourth utility" in manufacturing, but it’s one of the least efficient. Leaks in compressed air systems can waste up to 30% of generated air, directly translating into wasted electricity. Simple maintenance, such as tightening fittings, replacing worn hoses, and regularly cleaning filters, can reduce losses dramatically.
Additionally, lowering system pressure to the minimum required level prevents overworking compressors.
Action Point: Check compressed air systems weekly for leaks and inefficiencies. Even small repairs can deliver big energy savings.
6. Maintain and Calibrate Equipment Regularly
Poorly maintained machinery consumes more energy than well-maintained systems. Bearings that aren’t lubricated, belts that are worn, or misaligned motors all cause extra drag, leading to higher energy consumption.
Calibrating tools and equipment not only saves energy but also improves output quality. Predictive maintenance technologies, such as vibration sensors and thermal imaging, can help detect issues before they become costly.
Action Point: Create a preventive maintenance calendar and assign responsibilities to ensure regular inspections.
7. Switch to LED Lighting
Switching from fluorescent or incandescent lighting to LEDs is one of the simplest energy saving tips for businesses. LEDs use up to 75% less energy and last up to 25 times longer than incandescent bulbs. For workshops with long operating hours, the savings add up quickly.
LED lighting also provides better illumination, which can improve productivity and reduce workplace accidents.
Action Point: Start with the areas where lights are on most frequently, such as production floors and common areas, and gradually replace all fixtures with LEDs.
8. Install Smart Meters and Energy Monitoring Systems
Knowledge is power, and monitoring energy use in real time helps identify waste. Smart meters and sub-metering systems provide visibility into how much energy different processes consume. Some systems allow remote monitoring and alerts, so you can quickly act on abnormal spikes in usage.
Action Point: Install sub-meters for energy-intensive equipment to track their performance and identify opportunities for optimization.
9. Encourage Employee Involvement
Energy efficiency is most effective when embraced by everyone in the workplace. Employees can help reduce waste by turning off unused machines, reporting leaks, and following energy-conscious practices. Training programs and incentive systems encourage staff to adopt energy-saving habits.
Action Point: Create an energy awareness campaign in your workshop, and consider offering recognition for employees who identify significant savings opportunities.
10. Take Advantage of Natural Light and Ventilation
Where possible, make use of natural lighting through skylights or larger windows. This reduces dependence on artificial lighting and creates a healthier environment. Similarly, natural ventilation can lower cooling needs during certain seasons.
Action Point: Evaluate your facility layout to maximize daylight exposure and reduce reliance on artificial lighting.
Long-Term Energy Saving Tips for Businesses
Beyond immediate fixes, consider strategic investments that future-proof your facility:
· Renewable Energy Solutions: Explore solar panels or small wind turbines if feasible.
· Energy-Efficient HVAC Systems: Upgrade to high-efficiency units that offer greater performance at lower costs.
· Building Automation Systems: Integrate smart controls for lighting, HVAC, and equipment scheduling.
These measures may require higher upfront costs but yield substantial long-term benefits in both cost savings and sustainability.
Conclusion
Implementing these energy saving tips for businesses can make a measurable difference for small manufacturing facilities and workshops. From simple changes like switching to LED lighting and installing occupancy sensors, to larger investments such as VFDs and improved insulation, every step contributes to lower energy bills and enhanced operational efficiency. Energy efficiency is not only about saving money—it’s also about creating a more sustainable, competitive, and resilient business.
For small businesses looking to take action today, consider exploring product collections at Industrial Electrical Warehouse that support energy efficiency goals:
· LED Lighting Solutions – Reduce electricity costs with high-efficiency illumination.
· Smart Meters & Energy Monitoring Systems – Gain insights into real-time energy use.
· Motor Controls & Starters – Ensure motors run at peak efficiency.
By leveraging the right products and practices, your business can achieve lasting energy savings while boosting productivity.
