Watch: Six ways to eliminate hidden energy waste at your commercial facility
Energy waste is one of the most overlooked expenses in industrial and commercial facilities. Every kilowatt-hour used equates to money out the door, and with energy costs on the rise, bills are increasing faster than ever. The U.S. Department of Energy (DOE) industrial sector spends nearly $200 billion annually on energy.
The good news? The DOE estimates that more than 20% of the energy consumed in industrial and commercial facilities can be saved through cost-effective efficiency measures. By identifying and addressing hidden inefficiencies, you can significantly reduce operating costs, improve system reliability, and boost efficiency in the wake of rising energy prices.
Watch the full video above or read on to learn about six sources of hidden waste you may be missing.
1. Unnecessary running or idling
Equipment that runs when it’s not needed is a silent budget killer. Lights in empty hallways, pumps operating at low load, or chillers running 24/7 all consume energy without delivering value. In fact, idle equipment can account for 10–20% of total energy use in manufacturing.
What we recommend: Audit your facility for equipment being left idle and install smart controls to shut down systems when not in use.
2. Leaks
Think leaks only mean dripping pipes? Compressed air leaks, steam leaks, and heat loss from uninsulated pipes or poorly sealed windows are all leaks that represent wasted energy. Compressed air leaks alone can waste 20–30% of air supply, costing thousands of dollars per year per leak, depending on size and pressure.
What we recommend: Conduct regular walk-throughs and listen for hissing sounds. Use infrared cameras to detect heat leaks and prioritize insulation upgrades.
3. Friction loss
Dirty filters, clogged intakes, broken dampers, and poorly designed piping all create resistance, forcing fans and pumps to work harder. A clogged filter can increase fan energy use by 15%, and poor piping design can add more to pumping costs.
What we recommend: Maintain filters, repair dampers, and streamline piping layouts to minimize unnecessary friction.
4. Sub-optimized efficiency
Many systems are designed with generous safety margins, meaning they often operate far below their intended capacity. What wastes energy and money? Running multiple pumps when only one would suffice or keeping temporary chillers in place for months. Oversized systems can waste 15–25% of energy annually.
What we recommend: Review system design versus actual load. Shut down redundant equipment and remove temporary systems immediately.
5. Malfunctions
Faulty sensors, broken linkages, and inaccurate gauges can trick your system into operating inefficiently. Malfunctions can lead to 5–10% higher energy consumption and costly maintenance issues.
What we recommend: Inspect critical components regularly and confirm that signals match reality.
6. System imbalance
Variable frequency drives (VFDs) are designed to optimize energy use, but they can only do this if they’re properly configured. Running VFDs at 100% or leaving HVAC systems in simultaneous heating and cooling mode will create huge inefficiencies. In fact, improper VFD use can waste $10,000–$50,000 annually in large facilities.
What we recommend: Audit VFD settings and HVAC setpoints. Ensure systems are tuned for actual load conditions.
Get strategic about energy efficiency
By eliminating hidden energy waste, you can improve affordability, reduce maintenance headaches and strengthen your bottom line.
Start realizing significant savings by improving your facility’s energy performance. Our Strategic Energy Management (SEM) program helps organizations take a systematic, long-term approach to reducing energy waste—through training, tools, and continuous improvement practices.
Learn more about our SEM programs here: Strategic Energy Management Solutions | CLEAResult