Significant Cost Reduction in Manufacturing

The Power Of Energy Monitoring

Funded By:

Efficiency Manitoba

28%

Estimated Annual Electricity Savings

75%

Estimated Annual Maintenance Savings

Energy Utilization Monitoring

In this case study, PolySense Solutions used its proprietary AMP/BOLT technologies to monitor energy usage and utilization of 24 machines at a small manufacturing facility in Winnipeg, Manitoba.

Over the first two months of monitoring, PolySense was able to identify potential energy savings of $8500 annually, which represents a substantial 28% reduction in their current annual electricity expenditure. The majority of these savings were attributable to inefficiencies in three key machines - an air compressor, a wire electrical discharge machining (EDM) unit, and a rooftop HVAC unit.
The main air compressor was found to be operating at nearly 100% duty cycle due to several system leaks. In addition, the wire EDM machine was discovered to be left on standby mode and was never completely powered down, contributing to significant unnecessary energy expenditure. The rooftop unit was improperly programmed, with a poorly set thermostat leading to high power usage.

If these issues are rectified, energy consumption for these machines should be dramatically reduced. This client also benefitted from better visibility into their operations and equipment utilization due to the automatic data capture and reporting on the PolySense Platform

This case study illustrates the potential for significant energy savings in similar facilities through the use of advanced monitoring technologies like AMP and BOLT.

Sensors Utilized

PolySense AMP

With its ability to monitor the electricity usage of any equipment or circuit, the AMP provides comprehensive insights into energy consumption, usage patterns, and maintenance needs

Equipment Failure Energy Wastage
Polysense AMP

PolySense BOLT

The BOLT is a smart plug that revolutionizes energy management and asset monitoring.
With its intelligent capabilities and user-friendly interface the BOLT provides real-time data and analytics, empowering you to optimize energy consumption, schedule asset usage, and proactively address maintenance issues.

Downtime Detection Power Outages
Polysense BOLT

Manufacturing and Facility
Assets Monitored

asset1
CNC Milling Machine 1
asset2
CNC Milling Machine 2
asset3.png' %}
CNC Milling Machine 3
asset4.png' %}
Wire EDM Machine
asset5.png' %}
Pedestal Grinder
asset6.png' %}
Media Blaster
asset7.png' %}
Dremel Tool
fac-asset1
RoofTop HVAC
fac-asset2.png' %}
Shop Floor Lighting
fac-asset3.png' %}
Air Compressor 1
fac-asset4.png' %}
Air Compressor 2

Savings Discovered

Air compressor 1

Air Compressor.

Estimated Electricity Savings = $6000/year
Estimated Additional Savings = $1200

Changes to implement: PolySense Solutions found and measured 8 significant air leaks. Repairing these leaks will have a substantial impact on energy costs and equipment lifetime

Air compressor 1

Rooftop HVAC Unit.

Estimated Electricity Savings = $500/year
Estimated Additional Savings = $120/year + reduced maintenance

Changes implemented:
Thermostat was found to be on hold A/C mode 24/7.
Adjusted thermostat temperature and schedule so that a reasonable temperature was held during regular hours, and evenings.

Wire EDM (Electrical Discharge Machine)

Wire EDM (Electrical Discharge Machine)

Estimated Electricity Savings = $2000/year
Estimated Additional Savings = $2000

Changes to implement:
Shut the machine down at the end of each day. This machine was found to use over 3100 watts when sitting idle. Although there may be a few instances throughout the year where the machine needs to run for a few hours overnight, increasing the frequency of shutdowns will lead to substantial savings

Major Results

Reducing the duty cycle of both the air compressor and the Wire EDM unit from 100% to 30% for the remainder of their lifespan offers substantial economic advantages. By modifying the duty cycle, we extend the useful life of these units, thereby optimizing the return on the initial investment.

Furthermore, this adjustment results in reduced annual maintenance costs. Under the previous duty cycle, the maintenance cost would have been around 1% of the initial equipment cost per year. By lowering the duty cycle to 30%, the strain on the units significantly decreases, thereby cutting down maintenance costs.
Specifically, for the air compressor, originally costing approximately $60,000, the initial annual maintenance cost would have been about $600. With a conservative 20% reduction due to the lower duty cycle, the annual maintenance cost is now approximately $480. This results in a yearly saving of $120. Over the remaining 10-year lifespan, these savings amount to $1,200. For the Wire EDM unit, initially priced at approximately $100,000, the original annual maintenance cost was approximately $1,000. With the same 20% reduction due to the decreased duty cycle, the annual maintenance cost drops to around $800, generating a yearly saving of $200. Over the remaining 10 years of the unit's lifespan, this saving adds up to $2,000.

In summary
By extending the lifespan of the equipment and reducing maintenance costs over the next decade, the estimated total savings come to $3,200. This scenario highlights the considerable financial benefits of real-time monitoring and proactive management of critical assets.

Additionally, we have not factored in the costs associated with production disruptions that could occur from unexpected equipment failure due to high usage. The potential savings from avoiding these disruptions further underline the value of our strategy.

Ultrasonic Air Leak Detector

Ultrasonic air leak detector

Below are the eight(8) leaks we found.

leak leak leak leak leak leak leak leak

The ultrasonic leak detector helped us find the leaks in a noisy manufacturing shop environment. Once close, we could hear the leaks with our ears, and in some cases feel them with our hands. The leaks are severe enough that the air compressor is constantly running to compensate.

Conclusion

In conclusion PolySense Solutions, employing its advanced AMP/BOLT technologies, illustrated significant potential for energy savings in the manufacturing industry. Our intervention at this manufacturing facility allowed us to swiftly and non-invasively pinpoint inefficiencies, culminating in direct annual energy savings of $8500 if suggested changes in this report are implemented, which represents a substantial 28% reduction in their current annual electricity expenditure. These savings primarily arose from rectifying operational issues in three key pieces of machinery: an air compressor, a wire EDM unit, and a rooftop HVAC unit.
Additionally, addressing these issues will contribute to an indirect cost saving of $3200 for the client in the form of reduced maintenance on this equipment.

Moreover, our initiatives have considerably reduced the load on the electrical grid by 90,000 kWh each year, fostering environmental sustainability and enhancing the stability of the grid.
Our technology also enhanced the client’s operational visibility, enabling more effective management and optimal utilization of their equipment.

This case study underscores the transformative value that advanced monitoring technologies like our AMP & BOLT can offer to energy-conscious organizations, with substantial direct and indirect financial savings, environmental benefits, and operational efficiencies.

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