Energy saving – automatic shutdown of systems that are not working properly

Energy prices are rising. The pressure to reduce CO2 emissions _is growing. Businesses around the world are looking for effective ways to reduce their electricity consumption. How to do it? Often the simplest solutions bring the best results. One of them is automatic shutdown of devices that do not have to work continuously. In the case of industry, we are talking about such equipment as transporters, lighting or hydraulic units. It is worth taking a closer look at this.

Why is automatic shutdown of devices so important?

In many plants, devices operate continuously. Even when their operation is not needed at a given moment. Conveyor belts? Lighting in empty halls? Hydraulic units operating “in reserve”? This is everyday life. On the one hand, constant readiness increases the speed of response. On the other hand, it generates unnecessary losses. It is estimated that from 20 to even 30% of the total energy consumption in some plants comes from devices that could be switched off. The conclusion is simple. It is worth implementing automatic shutdown systems. Reducing energy losses brings savings without negatively affecting production processes. What’s more, less working machines also mean slower wear. And this is a double benefit.

In the context of managing and optimizing the operation of equipment in a plant, CMMS systems (Computerized Maintenance Management Systems) play an important role. They allow for monitoring machine operating time, planning maintenance based on actual consumption, and identifying equipment that is working inefficiently or is overused. By analyzing the data collected by CMMS, it is possible to make more informed decisions regarding automatic shutdown of equipment during periods of inactivity, which translates into real energy savings and extension of the life of the machinery park. These systems can also generate reports indicating areas in which the implementation of automatic shutdown will bring the greatest benefits.

Which devices are worth turning off automatically?

Of course, not all devices can be simply turned off. Safety and continuity of production are paramount. However, many systems are crying out for automation. For example, conveyor belts, which should not operate when there is no product. Presence sensors on the belts can effectively manage their on and off.

Lighting? There is also a lot of potential here. Lamps in warehouses, halls or corridors very often burn throughout the entire shift. Even where no one is present. Meanwhile, motion sensors or time schedules allow for huge savings.

The next category is hydraulic units. There are often situations in which the unit operates “just in case”, even though there is no demand for pressure. A system that monitors their operation and automatically switches them off after a period of inactivity can reduce unnecessary energy consumption and reduce the failure rate of systems.

It is also worth considering air conditioning and ventilation. HVAC systems can be adjusted to the actual load, employee presence or time of day. All so as not to cool or ventilate empty spaces.

Technologies supporting automatic shutdown

To effectively implement automatic shutdown of devices, you need the right tools. First, sensors. Motion detectors, presence sensors, photocells. They can control both light and the operation of conveyors or fans.

Timers are also great for simpler applications. Timers that turn devices on or off at specific times. Easy to install, cheap, and effective.

In larger plants, it is worth considering implementing a BMS (Building Management System). It allows for central control of many installations: lighting, air conditioning, ventilation, and auxiliary equipment. Thanks to data integration, the BMS can automatically optimize energy consumption in real time.

IoT devices are also becoming increasingly important. Smart sensors collect data on the operation of machines and systems. Analyzing this data allows for even better identification of areas where it is worth implementing automatic shutdown.

Implementing automatic device shutdown – step by step

How to implement such solutions? First, an audit will be needed. Without it, it is impossible to approach the subject professionally. You need to precisely measure which devices are working unnecessarily and how much energy they consume. The audit also allows you to determine the priorities of actions.

The next step? Choosing the right solutions. Simple sensors, advanced BMS, or maybe a hybrid approach? It all depends on the size of the plant, available budgets, and the specifics of the work.

The implementation itself should be done in stages. It is worth starting with the biggest energy “guzzlers”. Test solutions. Optimize.

Finally, monitoring. Regularly checking the effects of implementation and making corrections where needed. Because even the best system ceases to be effective if it is not properly managed.

Benefits of Automatic Device Shutdown

What can be gained by implementing such solutions? Although turning off devices may seem insignificant, in reality the benefits can be surprisingly large. Here are the most important ones:

• Firstly – lower bills. Even 10-30% savings on energy consumption is a result that cannot be ignored. Especially in times of rising electricity prices.
• Secondly – ​​lower CO2 emissions. And this is important today not only for the environment. It also counts in contacts with business partners or in assessing the company in terms of ESG standards.
• Thirdly – ​​longer life of devices. Less work = less wear = fewer breakdowns = lower repair costs.
• Fourth, a better corporate image. An organization that manages energy responsibly builds greater trust among customers, partners, and employees.

Saving energy by automatically turning off devices is a solution that combines simplicity of implementation with great effects. All you need to do is prepare well, choose the right technologies and consistently manage the process. In a world where every kilowatt-hour and every gram of CO2 matter, an intelligent approach to energy is not only sensible. It is simply necessary.