Manufacturing
Overview
Manufacturing has always been one of the most energy-intensive sectors in the U.S. economy, and the pressure to manage those costs has never been greater. In 2018, manufacturing accounted for 24% of all energy consumption in the United States, totaling a staggering 894,476 kWh. Today, energy prices have only continued to climb, making energy efficiency in manufacturing not just a best practice, but a competitive necessity.
Did you know many manufacturers miss out on huge sums from billing errors and mediocre utility pricing plans? Poor industrial energy management, or simply never having had the right systems reviewed, can quietly cost a facility tens of thousands of dollars each year. Finding the ideal utility pricing can be a time-intensive project, especially considering how many pricing options are available. Fortunately, when you partner with UMS, you can save both time and money!
Our experts do a detailed analysis of your electric, natural gas, and water bills — a true factory energy management review — so you don’t have to. Our industrial energy monitoring process examines your historical billing data to uncover overcharges, rate misclassifications, and pricing plans that simply aren’t working in your favor. Our data-driven approach has saved manufacturing companies across the United States hundreds of thousands of dollars.
Make saving easy by reaching out to us today!
What is Energy Efficiency in Manufacturing?
Energy efficiency in manufacturing means getting the most output from every unit of energy that your facility consumes, without sacrificing production quality or throughput. For most plants, that starts not on the floor, but in the billing office. Many facilities are unknowingly paying for more energy than they use, locked into rate structures that made sense years ago but no longer reflect their actual load profile.
True energy efficiency in industrial buildings is a combination of operational practices, smart equipment use, and making sure your utility provider is charging you correctly in the first place. That last piece is where most manufacturers leave the biggest money on the table, and it’s where Utility Management Services specializes.
Savings Numbers
| Type | Max Annual Savings | Average Annual Savings | Max Refund | Average Refund |
|---|---|---|---|---|
| All Manufacturing | $1,957,400 | $34,933 | $333,993 | $23,515 |
| Concrete/Mineral | $188,553 | $56,969 | ||
| Food/Beverage | $1,430,240 | $48,540 | $30,392 | $9,138 |
| Furniture | $671,671 | $74,275 | ||
| Lumber/Wood | $220,919 | $19,901 | $12,908 | $5,541 |
| Machinery/Electronics | $123,437 | $9,340 | $122,082 | $24,900 |
| Metals | $1,957,400 | $89,640 | $86,503 | $28,971 |
| Chemical/Petroleum | $97,723 | $16,570 | $71,912 | $23,266 |
| Paper/Printing | $182,620 | $18,401 | $29,350 | $29,350 |
| Plastics/Rubber | $131,259 | $22,843 | $17,157 | $9,177 |
| Textiles/Apparel | $147,598 | $22,112 | $128,061 | $43,045 |
Case Studies
Lyon Shipyard
Lyon Shipyard (LSI) has been serving the maritime industry as a top-notch repair facility in Norfolk, VA for over 80 years. Following an in-depth analysis, UMS experts discovered savings opportunities and utility bill errors that, once remedied, added up to hundreds of thousands of dollars in savings. Prior to our collaboration, LSI had suspected a billing error but did not have the time or expertise to investigate. By working with UMS, the company found their power provider had been billing them for an amount that greatly exceeded their needs, resulting in a $37,000 refund. This and other findings saved LSI over $233,000 a year without any added effort on the part of the company’s leadership team.
STF Precision is known for excellence in manufacturing high-tolerance cutting tools. STF creates high-quality diamond-tipped cutting tools, a specialty item that is famously difficult to produce. When STF approached UMS, the company sought a way to lower its natural gas and electric bills. After a full utility bill audit, including examining two prior years of billing data, UMS professionals found that STF was being overcharged. In the end, STF saved over $24,000 in ongoing savings without any operational changes or capital investments.
Prinston Pharmaceuticals
Prinston Pharmaceutical Inc. has specialized in manufacturing outstanding generic medication products for decades. In addition, they offer tailored solutions for their clients in the form of pharmaceutical contract manufacturing (CMO). The scientists at Prinston Pharmaceutical Inc are passionate about manufacturing generic products that increase patient access to otherwise expensive medication. In order to do that, they need to make sure their own costs are under control — which is where UMS came in. After analyzing 12 months of historical billing data from Prinston’s power provider, UMS experts were able to save the manufacturer over $80,000 with little to no operational changes.
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