Energy efficiency in packaging factories has become a critical competitive factor as manufacturers face rising costs and environmental pressures. With energy representing up to 20% of operational expenses in packaging facilities, the difference between an efficient operation and an energy-wasting facility can determine profitability. The packaging industry is energy-intensive by nature, consuming substantial energy resources from raw material extraction through manufacturing, distribution, and end-of-life management. 

When your facility runs three shifts and energy waste can consume a fifth of your operating budget, every kilowatt-hour becomes a competitive advantage.

Energy Efficiency in Packaging Factories Summary:

• Energy audits and monitoring systems identify 20-30% waste reduction opportunities in packaging facilities
• LED lighting retrofits reduce energy consumption by 66% with minimal disruption
• Variable frequency drives on motors can achieve 50% energy savings at 80% motor speed

What Are Your Quick Wins?

LED Lighting Conversion

Start with lighting, it’s the easiest improvement to implement. LED systems reduce energy consumption by over 66% compared to traditional metal halide systems. Install automatic sensors so lights operate only when areas are occupied. Where skylights exist, add automated dimming systems that adjust based on natural light availability.

Compressed Air Leak Detection

Every air leak costs approximately $1,320 per year. Schedule an ultrasound camera audit to identify leaks throughout your system. The average leak rate across industrial sites is 30%, making compressed air leaks one of the greatest sources of waste in industry.

Equipment Scheduling

Run energy-intensive operations during off-peak hours when electricity costs less. Most US utilities offer time-of-use (TOU) rates for commercial and industrial customers, dividing the day into different pricing periods. Peak hours typically occur during late afternoon to early evening (4 PM to 9 PM) with highest pricing, while off-peak hours during late night and early morning offer lowest pricing. By shifting energy-intensive packaging operations like thermoforming, sealing, and hot melt adhesive systems to overnight shifts or early morning hours, facilities can achieve significant electricity cost savings.

How Do You Find the Biggest Problems?

Conduct an Energy Audit

Hire a qualified third-party auditor to evaluate your facility. The audit should include:

• Historical energy billing analysis for 12 months
• Equipment inventory and operating hours assessment
• Compressed air system evaluation
• HVAC and lighting system review
• Production process energy profiling
  

Install Monitoring Systems

Deploy IoT sensors to track energy usage every 30 seconds across individual machines. Real-time monitoring reveals equipment running at partial capacity due to worn bearings or dirty sensors – issues that increase consumption while reducing output. 

Systems like Shoplogix can integrate multiple data sources to provide comprehensive visibility into energy consumption patterns across entire facilities. When connected to production data, these platforms identify correlations between production parameters and energy usage.

What Equipment Changes Save the Most Energy?

Variable Frequency Drives (VFDs)

Install VFDs on packaging machinery motors. When motor speed reduces to 80% of maximum, energy consumption often drops by 50% due to the quadratic relationship between speed and power. For packaging lines with frequent speed changes, this creates substantial cost reductions. High-efficiency motors and related interventions can save 20%-30% of energy used to drive powertrains. 

Heat Recovery Systems

Capture waste thermal energy from heating processes. Use heat exchangers to preheat water for washing processes or oil for production lines. These systems reduce reliance on fossil fuels while maximizing energy value. Excess heat is the world’s largest untapped energy source – capturing it means more value for what you are already paying for.

High-Efficiency Motors

Replace standard motors with IE4-rated synchronous motors. These provide 40% lower energy losses compared to IE3-rated motors. For constant torque applications, expect 2-5% savings with paybacks under one year.

Which Processes Waste the Most Energy?

Hot Melt Adhesive Systems

Glue pots are major energy wasters. Switch to cool melt adhesives that operate at lower temperatures with the same performance. You can reduce energy usage by 40% and consumption by 15-30%.

Compressed Air Operations

Compressed air systems are notoriously inefficient – 90% of energy used to produce compressed air is lost as waste heat. Focus on:

• Leak detection and repair programs
• Pressure optimization and right-sizing equipment
• Installing high-efficiency motors on compressors
• Adding leak detection and automatic pump down systems

Thermoforming and Sealing

These energy-intensive processes consume substantial electrical power. Optimize through:

• Process control systems to minimize energy spikes
• Equipment maintenance to maintain optimal performance
• Temperature optimization without affecting quality

Implementing Energy Efficiency in Packaging Factories

Step 1: Establish Leadership Support

Energy management requires C-level commitment. Without top management support, initiatives fail to achieve strategic benefits. The most successful energy efficiency programs in packaging operations combine multiple approaches: equipment upgrades, operational improvements, and advanced monitoring systems.

Step 2: Create Cross-Functional Teams

Set up teams to identify energy’s role in the value creation chain. Teams should include production floor personnel who have authority to take action and share benefits from results. Enforcing existing policies and regulations is just as critical as adopting more ambitious regulations.

Step 3: Set Baselines and Track Usage

Establish energy consumption baselines for every production line. Track usage regularly and link targets to unit manager performance evaluations. Manufacturing energy management platforms integrate production data with energy consumption to optimize both productivity and efficiency simultaneously.

Step 4: Implement Real-Time Monitoring

Deploy systems that provide production floor visibility of energy consumption. Staff need understanding and real-time data to make efficiency improvements. Advanced analytics offered by energy management systems can dissect energy usage data to uncover trends, inefficiencies, and opportunities for savings.

What About Building Systems?

HVAC Optimization

Use predictive maintenance systems with IoT sensors to monitor HVAC performance[Previous article content]. Address performance degradation that increases power usage before it becomes a major problem.

Building envelope improvements – better insulation, upgraded windows and doors, improved air sealing – reduce HVAC loads significantly. These upgrades require upfront investment but provide consistent returns over many years.

Refrigeration Systems

For facilities requiring temperature control, install high-efficiency motors that are 2-3% more efficient than older motors. Consider replacing high Global Warming Potential (GWP) refrigerants with low GWP alternatives.

Your Next Steps

This Week:

• Schedule compressed air leak detection audit
• Replace high-use area lighting with LEDs
• Review production schedules for off-peak energy opportunities
  

This Month:

• Conduct comprehensive third-party energy audit
• Install energy monitoring on highest consumption equipment
• Evaluate VFD opportunities on variable speed applications
  

This Quarter:

• Implement real-time monitoring system across facility
• Establish energy baseline for each production line
• Create cross-functional energy management team with clear targets
  

Final Thoughts on Energy Efficiency in Packaging Factories

Energy efficiency in packaging factories represents both an immediate cost reduction opportunity and a long-term competitive advantage. Facilities that implement comprehensive energy management systems will outperform those that don’t, especially as energy costs continue rising and environmental regulations tighten. The technology exists today to achieve substantial improvements in energy efficiency, and the financial returns justify immediate action.

The most successful energy efficiency programs in packaging operations combine multiple approaches: equipment upgrades, operational improvements, and advanced monitoring systems. 

What You Should Do Next 

Explore the Shoplogix Blog

Now that you know more about energy efficiency in packaging factories, why not check out our other blog posts? It’s full of useful articles, professional advice, and updates on the latest trends that can help keep your operations up-to-date. Take a look and find out more about what’s happening in your industry. Read More

Request a Demo 

Learn more about how our product, Smart Factory Suite, can drive productivity and overall equipment effectiveness (OEE) across your manufacturing floor. Schedule a meeting with a member of the Shoplogix team to learn more about our solutions and align them with your manufacturing data and technology needs. Request Demo