Make energy efficiency improvements this autumn, reap the benefits over winter
As winter production approaches, machinery may soon face colder temperatures, damp conditions and increased demand. An autumn maintenance review gives you time to spot inefficiencies, plan improvements and reduce the risk of avoidable disruption during the months ahead.
Start with an audit of your machinery. Review energy use, maintenance records and any changes in performance. Look for equipment that runs hot, vibrates excessively, needs frequent adjustment or has a history of unplanned stoppages. Prioritise the machines that are most critical to production, then decide which issues can be addressed during planned maintenance.
The right improvements can help reduce wasted energy and support more reliable production through winter.
Replace inefficient motors
Motors that are old, poorly matched to their application or showing signs of wear may use more energy than necessary. Check for changes in vibration, noise and operating temperature, and investigate whether the motor is correctly sized for the load it drives.
If replacement is being considered, compare the whole-life costs of repair and replacement. An IE3 or IE4 motor may offer improved efficiency, but the best option depends on the motor’s duty, operating hours, load profile and compatibility with the rest of the system. A motor specialist can help assess the application before you invest.
Improve belt drive efficiency
A belt drive that is incorrectly tensioned, misaligned or paired with worn pulleys can waste energy and wear prematurely. Any slippage, excessive internal friction, and mechanical drag can drain efficiency through power loss.
During an inspection, check belt condition and tension, pulley alignment and pulley wear. Replace damaged components and make sure replacement belts are suitable for the drive and operating conditions.
Many drives also need their tension check again shortly after a new belt is fitted. Following the manufacturer’s guidance can help prevent slip and unnecessary wear.
For more trouble shooting advice, see top causes of v-belt failure
Check bearings and seals
Bearings operating outdoors in harsh condition may be exposed to moisture, dirt and temperature changes. Check that the bearing, housing, lubricant and sealing arrangement are suitable for the application and its working conditions.
Inspect seals for damage or deterioration, as failed seals can allow contaminants to enter and shorten bearing life. Unusual noise, rising temperature or changes in vibration can indicate that a bearing needs further investigation.
For more warning signs, read 5 signs you should replace your bearings before it’s too late
Reduce compressed air leakage
Small, compressed air leaks can go unnoticed, yet they force the system to work harder to maintain pressure. Check pipework, joints, fittings and connections for leaks, and repair or replace damaged sections.
Also review whether pipes are correctly sized for the required flow and whether the equipment is suitable for the application. Fixing leaks and addressing restrictions can reduce wasted energy while helping the system deliver air where it is needed.
Optimise lubrication
Both over-lubrication and under-lubrication can lead to excess friction, heat and premature component wear. Review lubrication intervals, quantities and lubricant types against the equipment manufacturer’s recommendations and the conditions in which the machinery operates.
Pay particular attention to bearings in compact or hard-to-reach locations, where manual lubrication points may be missed. Automatic lubricators can help deliver lubricant at controlled intervals in suitable applications. Before winter, check that the grease or oil selected is appropriate for the expected operating temperatures.
Improve automation efficiency
Automation can help make processes more consistent and reduce avoidable energy use, particularly during busy production periods. Review where controls, sensors or automated systems could reduce unnecessary running, improve process timing or provide clearer information about equipment performance.
Start with the needs of the process. Check that equipment is correctly set up, maintained and integrated with the wider system. Automation is most useful when it addresses a specific inefficiency and can be monitored to confirm the result.
Plan improvements before winter
An autumn audit gives maintenance teams time to assess priorities, source components and schedule work around production. Focus first on the changes that can improve reliability and reduce wasted energy on critical equipment.
By addressing developing issues before winter demand peaks, you can help machinery run more efficiently and give your team a stronger foundation for productive, reliable operations.
Get in touch with our product experts for your free winter reliability walkthrough (T&C’s apply)*
* Terms & Conditions: Only one free booking slot per month will be available in this offer. If demand is high, we will advise you on available dates. Alternatively, you could schedule a call to discuss your problems with one of our product specialists.
Travel and accommodation requirements are not included in the free service, these will be charged to your company at standard mileage and accommodation rates and all cost will be agreed in writing with yourself before the work is undertaken.
Please contact us if you have any questions