Energy conservation program

An energy conservation program is an organised, continuing effort in an industry to reduce energy use per unit of production by eliminating waste and using efficient equipment and practices, while keeping output, quality and safety the same.

Elements / steps of the program

1. Management commitment and energy policy – top management sets targets (e.g. 10 % reduction in kWh/unit in 2 years) and allocates budget.
2. Energy manager and team – appoint a responsible energy manager and a committee from production, maintenance and finance.
3. Energy audit – study present energy use, measure loads, find losses and list energy saving opportunities with costs and payback.
4. Set targets and action plan – rank measures as no-cost, low-cost and capital projects.
5. Implementation – carry out measures such as:
   • load scheduling and shifting to off-peak tariff hours,
   • power factor correction to reduce kVA demand,
   • energy-efficient motors, VFDs on pumps and fans,
   • efficient lighting (LED, electronic ballast, daylight, sensors),
   • fixing compressed air leaks, insulation of hot surfaces,
   • waste heat recovery, good maintenance.
6. Monitoring and targeting – meter each section, track specific energy consumption monthly, compare with targets.
7. Training and awareness – train operators, display posters, reward savings; "switch off when not in use" culture.
8. Review and repeat – evaluate results, report savings and update the program.

Commitment → Audit → Targets → Implement
     ↑                             ↓
   Review  ←  Monitor & train  ←───┘

Benefits: lower production cost, reduced demand on the national grid (less load shedding), lower emissions and better competitiveness.