CUT COSTS, NOT CORNERS: HOW TO SLASH ENERGY USE IN YOUR PLANT
Keen to reduce your energy spend and boost the performance of your plant at the same time?
You’re not alone – with power prices constantly on the rise, more and more businesses are looking for ways to run leaner, smarter, and more sustainably. The good news is, with the right projects and a solid plan, you can cut energy use without cutting productivity.
Step One: Set your baseline so you know what you’re working with
Before you can start saving energy, you’ve got to understand how much you’re using – and where it’s going. Think of this as your energy “health check.”
- Pull your power bills
Start with 12 months of electricity bills to get a picture of your seasonal highs and lows. Look at total kWh used, peak demand charges, and time-of-use tariffs. This helps you identify patterns – like spikes during certain times or shifts. - Walk the floor
Do a physical walk-through of your plant to get a feel for what’s running, when, and why. You’ll often find equipment left running unnecessarily, or areas that are over-lit. - Install smart energy meters
This is where the real gold is. We can install sub-meters on different parts of your plant – for example, lighting circuits, air compressors, or specific production lines. This lets you see exactly which areas are guzzling power. - Log it and learn
Once your monitoring is up and running, gather data for a few weeks or months. The longer you track, the clearer the picture. This data forms the benchmark you’ll use to measure improvements against.
Step 2: Set reduction targets
Most sites can realistically aim for 10–20% energy reduction in the first 12–18 months with the right changes in place.
Step 3: Prioritise projects with quick wins & then plan for long-term gains
Start with low-cost, high-impact projects – think lighting, compressed air, or power factor correction.
Bigger upgrades (like automation, motor control, or load management) take longer but can deliver serious savings.
- LED Lighting Upgrades
Lighting can account for up to 30% of your total energy bill. Swapping old halogens or fluorescents for high-efficiency LEDs cuts consumption and improves light quality on-site. - Power Factor Correction (PFC)
Poor power factor means you’re paying for power you’re not even using. A properly sized PFC unit can reduce your demand charges and improve equipment life. - Compressed Air Optimisation
Leaks, poor control, or outdated systems are common culprits for energy waste. Upgrades or simple repairs can have a massive impact. - Automation & Control Systems
Automating equipment to run only when needed can save thousands – particularly on processes that don’t need to run 24/7.
Step 4: Monitor and maintain
Use smart monitoring tools for energy use and load management to track how you’re going with your energy savings.
With a strong focus on energy management you can lower power bills, reduce downtime, improve working conditions with better lighting and smarter systems as well as achieving the environmental wins.
How EAS Can Help
At EAS, we don’t just throw gear at the problem – we take the time to understand your site, your goals, and what success looks like for your team. Whether you want a full plant-wide energy audit or just need help swapping out some lights, we’ve got the know-how and the crew to get it sorted.
Ready to Get Started?
If you’re keen to start trimming your energy bills and future-proofing your plant, get in touch with the EAS team or give us a bell on 07 834 0505 – let’s make your plant work smarter, not harder.
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