Permanently Reduce Energy Costs
in Manufacturing –
Measurable, ISO 50001-Compliant

Compressors, furnaces, presses, drives – manufacturing operations contain enormous savings potential that remains invisible without structured monitoring. Alligator Analytica delivers machine-level transparency and the key performance indicators required for sustainable ISO 50001-compliant optimisation.

15–22 %
typical energy savings
45 %
BAFA subsidy possible
6–12
months to payback
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The 3 Biggest Energy Consumers
in Manufacturing

In most manufacturing plants, 70–80 % of avoidable energy costs arise in the same three areas – often unnoticed because the measurement points are missing.

01

Compressed Air & Compressors

Compressed air is one of the most expensive energy forms in industry – with an efficiency of often below 10 %. Leakages, incorrect pressure levels and unnecessary standby operation cost mid-sized plants €20,000–80,000 per year without anyone noticing.

Typical Savings Potential
15–30 % of compressed air energy consumption through leak detection and load optimisation
02

Heat, Furnaces & Thermal Processes

Industrial furnaces, drying systems and process heat have often grown historically – with fixed temperature profiles and no load adjustment. Heat losses from poor control and uninsulated pipework accumulate significantly over time.

Typical Savings Potential
10–25 % through load-responsive control, waste heat recovery and optimised ramp-up profiles
03

Drive Technology, Presses & Idle Times

Oversized motors, presses in standby and machines idling between shifts are silent cost drivers. In manufacturing plants, idle times typically account for 15–40 % of total machine running time.

Typical Savings Potential
8–20 % through automatic idle detection, switching commands and peak load capping

Typical Savings Targets –
and What Drives Them

The figures are based on real projects with manufacturing companies employing 50–500 staff across 1–5 production sites.

15 %
Shift Comparison & Idle Detection
Through transparency alone, with no additional investment – the foundation for all further measures
+5 %
Compressed Air Optimisation
Leak localisation, pressure level reduction, deactivation of standby compressors
+3 %
Thermal Control Optimisation
Load-responsive temperature profiles, waste heat recovery, optimised ramp-up curves
≥22 %
Total Savings (Combined)
When all identified measures are consistently implemented within an ISO 50001 framework
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Case Study · Manufacturing

Metal Processing Plant, 180 Employees, North Rhine-Westphalia

2 production sites, 3.2 million kWh annual consumption, no digital metering – energy reporting based solely on annual invoices. ISO 50001 certification was a management objective.

Installation period 6 weeks
ISO 50001 certification after 5 months
Identified savings – 18.4 % (≈ €118,000/year)
BAFA BEW Module 3 35 % grant (medium-sized company)
Payback (net) approx. 8 months
Typical Findings After 4 Weeks
  • Compressed air systems continue running outside shift hours in over 60 % of plants
  • Peak loads frequently caused by 3–5 machines starting simultaneously – avoidable through staggered start-up
  • Identical machines consume up to 25 % more energy depending on maintenance condition
Supported Protocols & Systems
M-Bus Modbus RTU/TCP OPC-UA PLC MQTT SCADA

Further Reading

Implementing ISO 50001 BAFA Subsidy up to 45 % Calculate Peak Load Costs Energy Audit DIN EN 16247 What Does an EMS Cost?

Ready to Make Your Manufacturing
Energy Fully Transparent?

In a free initial consultation, we show you exactly which savings potential exists in your production – and how you can take advantage of BAFA funding.

Check Your Potential Now Calculate Your Savings →