Saving energy in industrial plants

Darijo Stankovic

November 17, 2025

Saving energy in industrial plants

Saving energy in industrial plants: How intelligent controls, LED lighting and maintenance reduce costs

Increasing energy costs and ever stricter emissions regulations mean that energy efficiency is no longer a luxury for industry, but a necessity. Experts emphasize that one of the best starting points is to optimize the control system — the “brain” of production plants. Modern controls can reduce energy consumption, costs, and emissions, while outdated systems have the opposite effect.

‍

Start with an energy analysis

The first step is to understand where the energy is going. An energy audit uncovers the biggest energy consumers and shows where investments are a priority. After the analysis, you can focus resources on the plants and processes that yield the greatest savings.

‍

Modernization of components and variable drives

Outdated components are often the silent cause of energy losses. Replacing inefficient control devices, sensors and actuators with modern, energy-saving alternatives can significantly reduce consumption. The installation of frequency inverters (VFD) on motors is particularly effective. VFDs adjust the speed to the actual load so that the motor does not run at full power when not required. In practice, this can reduce motor energy consumption by up to 30 percent or more.

‍

Advanced PLC programming and automation

The software of the control system is just as important as the hardware. By implementing energy-saving modes during periods of low load and predictive algorithms that optimize consumption in real time, unnecessary energy consumption can be avoided. Modern plants also use SCADA systems, which monitor consumption in real time; analyzing this data helps to quickly identify inefficient processes.

The next stage is automation. The integration of intelligent sensors, IIoT devices, and modern PLCs enables precise process control and reduces human errors. For example, the system can shift production tasks to periods with low electricity tariffs, synchronize the operation of machines to avoid idle times, and activate energy-saving modes when plants are idle.

‍

Regular maintenance and calibration

Even the best systems require regular maintenance to operate at maximum efficiency. Routine inspections and calibrations ensure that sensors, controllers, and other components function precisely. Poorly calibrated equipment can cause significant energy losses. Scheduled preventive maintenance also reduces the risk of failures and ensures that all systems meet technical specifications.

‍

LED lighting as a quick gain

In addition to control systems, lighting is a significant energy consumer in halls, warehouses and offices. The US Department of Energy notes that LED lights use at least 75 percent less energy and last up to 25 times longer than incandescent lamps. Their directed light reduces the need for reflectors and diffusers, and the long lifespan means fewer replacements and lower maintenance costs. Replacing outdated lighting with LED technology therefore often results in quick and measurable savings.

‍

Tips to get you started

‍

Analysis of consumption — conduct an energy audit and identify the biggest consumers
Modernize your equipment — invest in frequency inverters, energy-efficient controls and sensors, and LED lighting.
Introduce intelligent controls — use advanced PLC programs, SCADA monitoring, and IIoT devices to optimize processes in real time
Schedule work at convenient times — synchronize energy-intensive tasks in times of low tariffs and reduce idle times.
Maintain and calibrate — regular inspections and calibrations keep your system in top shape.

‍

Energy efficiency is not a one-off project, but a continuous improvement process. By making intelligent investments in control systems, automation, LED lighting, and preventive maintenance, you can significantly reduce operating costs while reducing your company's carbon footprint.

‍