Cutting Energy Use with Automation: The 90-Day Plan

Energy costs have become the second-largest variable expense in many factories. The good news: automation systems already collect the data needed to improve energy performance. This 90-day plan shows how to turn your control network into an energy-management tool — without new hardware.

Phase 1: Audit and Baseline (Days 1–30)

• Enable energy counters in drives and PLCs.
• Use SCADA or historian data to establish baseline kWh per product or batch.
• Identify major loads — compressors, ovens, pumps, and HVAC.
• Correlate consumption with production states (run, idle, standby).

Phase 2: Optimization (Days 31–60)

• Implement auto-shutdown logic for idle equipment.
• Reduce compressed-air leaks through continuous monitoring.
• Apply variable-speed drives where feasible.
• Use predictive control for peak-load shaving.

Phase 3: Visualization and Governance (Days 61–90)

Display key metrics on operator HMIs and energy dashboards. Track kWh per unit and CO₂ savings weekly. Create alerts for abnormal usage patterns using your existing MES or historian system.

Case Example: Injection Molding Plant

A plastics plant reduced total energy use by 12% in three months using PLC-based scheduling and automatic compressor sequencing — no additional sensors were required.

Related Articles

• From OEE to OGE: Tracking the Energy Side of Efficiency
• Smart Sensors for Compressed Air Leaks: Fast Payback
• Sustainability Dashboards That Engineers Actually Use

Conclusion

Energy optimization doesn’t start with new technology — it starts with better use of what’s already automated. Within 90 days, plants can cut consumption and reveal hidden capacity for sustainability gains.