Manufacturer reveals hidden energy consumption

A global player in the field of specialised printing wanted to gain a better understanding of where energy was being consumed when production was at a standstill. A targeted measurement campaign carried out by Encon revealed this hidden consumption and identified a technically achievable annual savings potential of approximately 207,000 kWh.

High base load remains hidden outside production hours

During the annual energy audit, Encon found that electricity consumption remained strikingly high during non-production hours. However, the existing systems did not provide sufficient detail to determine which consumers were causing this base load.

This made targeted intervention difficult. After all, without insight into the individual consumers, it is unclear which installations need to remain active and where energy consumption outside production hours can be avoided. Encon therefore proposed supplementing the general energy audit with a separate zero-load savings project.

Targeted measurements reveal energy consumption step by step

Encon organised an extensive measurement campaign across various low-voltage switchboards and associated installations. The team combined quarter-hourly data, logging and detailed measurements to further break down electricity consumption during non-production hours.

The added value lay not only in the collection of measurement data. Encon translated the results into concrete energy profiles and identified which consumers should be addressed as a priority. As a result, the company not only gained insight into where the base load originated, but also received concrete tools to reduce consumption structurally.

Measurement data becomes a concrete savings programme

The analysis identified potential savings in areas including standby power loads, HVAC systems, process installations and lighting. Taken together, the technically feasible measures represent a potential saving of approximately 207,000 kWh per year, or around €39,900 in annual energy costs.

In addition, the company now has a clearer overview of its total non-production energy consumption. This makes it possible to prioritise investments and actions more effectively and to monitor energy management on an ongoing basis. In this way, the measurement campaign not only delivers energy savings on paper, but also provides a practical basis for systematically reducing costs and unnecessary consumption.