Energy consumption reduction by 19% in Grójec
Tariff analysis and changing the work cycle of induction furnaces allowed for huge savings with zero equipment investment.
At Agro-Przetwórstwo Grójec, electricity bills grew by 12% each quarter. Instead of spending a fortune on new machines, we checked how to use existing furnaces during cheaper tariff hours.
The challenge
The plant paid an average of 43,150 PLN net per month for electricity. The biggest problem was 3 induction furnaces working at full power between 10:00 AM and 1:00 PM. This is exactly when the energy tariff is most expensive. Additionally, the company paid penalties for exceeding contracted capacity – an average of 1,730 PLN every month. This happened because operators turned on all machines simultaneously after morning coffee, causing a sudden spike in consumption.
Our approach
Our 3-person team spent 9 business days on the floor. We installed 4 portable energy meters to check the real consumption of each machine individually. We analyzed invoices from the last 13 months and compared them with the work schedule of 27 production employees. We looked for moments when energy is cheapest and furnaces can work without interrupting the technological flow. We count every penny, so we rejected the idea of buying new capacitor banks for 84,000 PLN.
The solution
We proposed a simple plan: shifting the heaviest melting process to night hours (10:00 PM – 6:00 AM). We changed the schedule for 6 operators, introducing a night shift allowance which was still a fraction of the savings amount. We also introduced a strict 14-minute gap rule during the startup of main motors in the morning. This avoided penalties for contracted capacity. Additionally, we sealed the compressed air installation, eliminating 16 minor leaks that caused the compressor to work 2 hours too long daily.
Results
In the first month after the changes, the bill dropped by nearly one-fifth, and work on the floor became more organized.
Timeline
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November 5, 2024Meter installation and start of measurements on the floor
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November 14, 2024Tariff analysis and 13-month invoice review
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November 21, 2024Implementation of new shift schedule for operators
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November 28, 2024Repair of leaks in the compressed air system
"Honestly, I feared a worker revolt over night shifts. It turned out that the financial bonus and less noise during the day suited them. We save over 8 thousand a month without buying a single new screw."