Useful tips for saving energy in Industrial Sector


Read our Energy Efficiency tips on National Energy Conservation Day, our effort to make industries more energy efficient.


  • Optimize the tariff structure with Distribution company
  • Schedule your operation to maintain high load factor
  • Minimize maximum demands by tripping unessential loads through demand controller
  • Use APFC panel to correct power factor to unity under rated load conditions
  • Disconnect primary power to transformers that do not serve active loads
  • Use stand by electric generation equipment for on-peak high loads
  • Check utility meter with your own meter


  • Use properly sized motors matching with the load for optimum efficiency
  • Use energy-efficient motors where economical (High efficiency motors provide 4-5 % higher efficiency than standard motors).
  • Use synchronous motors to improve power factor
  • Check for under voltage or over voltage conditions
  • Provide proper ventilation (for every 10 c rise in temperature over recommended, motor life is estimated to be halved)
  • Demand efficiency restoration after motor rewinding (If rewinding not done properly, the efficiency can reduced by 5-8%)


  • Use variable speed drives for large variable loads
  • Use high efficiency gear sets
  • Use precision alignment
  • Check belt tension regularly
  • Eliminate variable pitch pulleys
  • Use flat belts as alternatives to V belts
  • Use synthetic lubricants for large gear box
  • Eliminate eddy current couplings


  • Use smooth well rounded cones for air intakes
  • Avoid poor air flow distribution at the air inlet
  • Minimize fan inlet and outlet obstructions
  • Clean screens, filters, and fan blades regularly
  • Use aero foil shaped fan blades
  • Eliminate leaks in air ducts
  • Minimize bends in air ducts
  • Turn fan and blower off when not needed


  • Operate pump near best efficiency points
  • Modify pumps to minimize throttling
  • Adapt to wide load variations with variable speed drives or sequenced control of smaller units
  • Stop running both pumps – add an auto start for online spare or add a booster pump for a problem area
  • Ensure proper seals and packing to minimize water waste
  • Increase fluid temperature differentials to reduce pumping rates in case of heat exchangers
  • Avoid pumping head with free fall return ; use siphon affect to advantage


  • Consider variable speed drive for variable load on positive displacement compressors
  • Use a synthetic lubricant if compressor manufacturer permits it
  • Be sure lubricating oil temperature is not too high ( oil degradation and lowered viscosity) and not too low ( condensation contamination )
  • Change the oil filter regularly
  • Periodically inspect compressor inter coolers for proper functioning
  • Use waste heats from a very large compressor to power am absorption chiller or preheat process or utility feeds
  • Establish a compressor efficiency maintenance program. Start with an energy audit and follow up , then make a compressor efficiency maintenance program a part of your continuous energy management program

Sharing is caring!