As energy costs continue to surge and sustainability remains a critical focus, manufacturers are being urged to adopt a turnkey approach to energy management to achieve measurable cost savings.
According to Mark Walton, sales director at adi Facilities Engineering, a comprehensive, end-to-end energy management solution is no longer a ‘nice-to-have’ – it’s a necessity.
“Manufacturers can no longer afford to tackle energy management in silos,” said Walton. “A holistic approach, addressing one issue at a time, only scratches the surface. True cost savings and efficiency gains come when you integrate monitoring, data analytics, and proactive maintenance into a single, streamlined system.”
Turnkey energy management provides manufacturers with a full-service solution, covering everything from initial energy audits and strategy development to technology implementation, monitoring, and ongoing optimisation.
“One of the pillars of this approach is real-time data monitoring,” explained Walton. “This involves the deployment of intelligent sensors and sophisticated software systems that continuously track energy consumption across all facilities. This constant stream of data provides manufacturers with immediate, actionable insights into where and when energy is being wasted, allowing them to promptly address inefficiencies.”
“Ultimately, the value of data can’t be understated – predictive analytics, for instance, allow manufacturers to monitor equipment performance, identifying potential issues before they escalate into costly breakdowns. That way, manufacturers can prevent unplanned downtime and extend the lifespan of critical machinery, all while keeping energy use in check.”
Continuous optimisation creates an ongoing cycle of improvement, where energy usage patterns are regularly reviewed and systems are adjusted to maintain peak efficiency. It’s certainly not a one-time fix, but a dynamic process that evolves alongside a business’s operations, ensuring energy strategies remain effective and responsive to changing demands.
“Beyond the financial advantages, this integrated approach is also a powerful tool for sustainability, which is an increasing area of focus for manufacturers in a range of industries,” Walton explains.
“By cutting energy waste and reducing carbon emissions, manufacturers not only lower their operational costs but also strengthen their environmental credentials.
“Using real-time data and predictive analytics means manufacturers stop simply reacting to rising energy costs
“Instead, they start controlling and reducing their consumption in a way that drives both financial and environmental benefits.”
Manufacturers who adopt a turnkey approach to energy management can see a reduction in energy costs of typically up to 30%, with additional savings from reduced downtime and extended equipment lifespan.
As regulatory pressures mount and energy prices show no signs of stabilising, Walton urges manufacturers to rethink their energy strategies: “It’s not just about cutting costs — it’s about future-proofing operations. The longer businesses delay adopting a turnkey approach, the more money they leave on the table.”
