CASE06 · Manufacturing · Injection, extrusion and utilities
Mapping injection and extrusion electricity with one-minute operating patterns
Individual equipment metering separates production machines from cooling, HVAC and compressed-air loads. One-minute profiles identify priorities after a large year-on-year increase in factory electricity use.
01 · CASE ANALYSIS
Operating challenge
May 2022 factory electricity reached 221,940 kWh compared with 142,704 kWh in May of the previous year, an increase of approximately 55%. Monthly totals alone could not explain which loads caused the increase.
Cooling, HVAC and compressed air were large supporting loads. Machine operation, stopping and standby needed to be compared with auxiliary equipment behavior.
02 · CASE ANALYSIS
Metering and consumption structure
The analysis combined monthly electricity, peak demand and power factor with individual metering of six injection machines, nine extrusion machines and NC equipment. Dedicated chillers, first- and third-floor AHUs, compressors and dust collectors were also measured.
One-minute and 24-hour power profiles were used to compare running, stopping and standby patterns. Average factory load was approximately 298 kW. Process-level shares include associated cooling; end-use shares separate cooling from the production machines.
| Process | Average power | Share |
|---|---|---|
| Injection, including dedicated cooling | 59.1 kW | 19.8% |
| Extrusion, including dedicated cooling | 73.0 kW | 24.5% |
| HVAC | 80.8 kW | 27.1% |
| Compressed air | 28.9 kW | 9.7% |
| NC equipment | — | 2.0% |
| Dust collection | — | 4.3% |
| Office, lighting and other | — | 12.7% |
03 · CASE ANALYSIS
Diagnostic priorities
HVAC was the largest single end-use area, making production-linked schedules and setpoints a priority. Injection and extrusion machines needed to be reviewed together with their dedicated cooling.
Compare old and new compressors for concurrent operation, loading/unloading and demand response. Check whether chillers continue running during stopped or low-load production.
04 · CASE ANALYSIS
Evidence and follow-up M&V
This is a measured consumption-structure diagnosis. The report does not state a confirmed savings quantity or financial saving for a specific implemented measure.
After operating or equipment improvements, compare energy under equivalent production conditions and account for operating hours and auxiliary demand. The +55% increase must not be presented as a savings rate.
| End use | Share |
|---|---|
| Injection machines | 14.8% |
| Extrusion machines | 20.5% |
| Dedicated chillers | 8.9% (26.7 kW) |
| HVAC | 27.1% |
| Compressed air | 9.7% |
| NC / dust collection / other | 2.0% / 4.3% / 12.7% |
05 · CASE ANALYSIS
Engineering lesson
Meter production and utility loads on the same time axis. The combination reveals standby and operating interlocks that a factory monthly bill cannot show.
APPLY TO YOUR SITE
Connect your operating data to an actionable energy strategy.
Discuss the measurement boundary, data quality, operating constraints and verification approach for your facility.
Discuss your project All English cases