Conocer el consumo eléctrico de tu empresa es fundamental para ahorrar electricidad durante el proceso de producción, lo que repercute muy positivamente en la competitividad del negocio frente a la competencia. Existen muchas formas de ahorrar electricidad, pero hoy os vamos a mostrar el sistema de Energy Sentinel, el gestor del ahorro energético del que ya hablamos en una entrada anterior, y que ha conseguido estimar una reducción del 13% anual para la empresa cerámica Cevica.

Este caso de éxito para ahorrar electricidad consiste en la monitorización de las principales máquinas de la empresa y su gasto energético. Teniendo en cuenta la progresión al alza de los precios de la energía y la coyuntura económica actual, es imprescindible la adopción de medidas que permitan optimizar los recursos de la compañía, ya que en algunos casos son tan importantes como para mantener la posición en el mercado o, incluso, asegurar la supervivencia de la empresa.

Tal como explican desde Energy Sentinel, la propia compañía se encargó de orientar sobre los principales factores de consumo para detectar los puntos de mayor pérdida de energía eléctrica, dejando para una segunda fase los otros consumos derivados de sus producción (agua, gas etc.).

Una vez realizado el inventario, se decidió monitorizar las siguientes áreas de Cevica, que suponen el 85% del consumo eléctrico total de la factoría:

  • Nave general
  • Bombos
  • Esmaltadora
  • Prensas

El consumo eléctrico bajo la lupa

Para hacer el seguimiento, se instalaron de forma rápida y sencilla una serie de medidores y un datalogger en el cuadro eléctrico, el lugar idóneo para centralizar el acceso a los técnicos de la monitorización, y estos son los datos reales del consumo que se obtuvieron:

  • El consumo mínimo (stand by) en periodos de no producción es de 11,83 kWh de media anual. Este consumo se ha tenido en cuenta en un domingo cualquiera y el día 15 de agosto, días en los que no existe producción, ni actividad alguna en la empresa.
  • Para un día normal entre semana el consumo mínimo es de aproximadamente 80 kW con picos máximos semanales de 180 kW.
  • Las esmaltadoras trabajan desde las 6:45 h hasta las 21 h (horario de tarifa “Punta”, en gran parte). El consumo es de 22,50 kWh en periodos de máximo consumo eléctrico, con mínimos de 5 kWh, en periodos de no producción. Una vez terminada la jornada laboral, las líneas se desconectan completamente para que no queden consumos “stand by” nocturnos.
  • No obstante, los bombos trabajan en horarios de tarifa económica, pudiendo así ahorrar electricidad de forma importante en la factura de la luz. Durante el día, se realizan labores de descarga, limpieza y carga de material para el día siguiente.
  • En lo referido a las prensas, estas trabajan desde las 08:00 h hasta las 21 h Los picos máximos detectados son de 60 kWh, pero, a diferencia con las esmaltadoras, aquí sí se encuentran consumos nocturnos cuando no hay producción que se elevan 4 kWh.

Muestra general del consumo eléctrico de CEVICA y recomendaciones para ahorrar electricidad
Muestra general del consumo eléctrico de CEVICA y recomendaciones para ahorrar electricidad

En la imagen se muestra el consumo eléctrico general de la empresa Cevica, con claros picos de consumo durante el día y consumos latentes en las horas de cierre, lo que significa que existe un buen margen de reducción de la factura de la luz. También se muestran las recomendaciones para ahorrar electricidad y que puedes descargar más abajo de forma completa.

Conclusiones para ahorrar electricidad

Tras dos meses de mediciones, Energy Sentinel analizó la información obtenida para extraer diversas conclusiones y recomendaciones para ahorrar electricidad en la empresa de cerámica:

  • Realizar un esfuerzo de localización y control de consumos latentes. El sumatorio del consumo eléctrico de este tipo de gasto puede suponer un ahorro de un 6-8 % en la factura anual. Efectivamente, para un día de actividad normal, el consumo mínimo es de 80 kWh pero se detectan consumos en periodo de inactividad relativa e, incluso absoluta, de en torno a los 12 Kwh diarios, parte de ellos bajo tarifas altas.
  • El consumo en los bombos puede ser objeto de mejora, al restringir aún más su uso a horarios de mínimo coste energético, siempre y cuando no se vea afectado el ritmo de producción. Este cambio supondría un ahorro de un 1-2 % en la factura anual.
  • Del mismo modo, convendría estudiar el trabajo realizado por esmaltadoras y prensas para trasladar su actividad a horarios más económicos, al menos en parte. Ello supondría un ahorro de 2-3 % de energía eléctrica, con la consiguiente reducción en la factura.
  • De lo anterior, también puede deducirse un mejor control de la potencia contratada y ajustarla a los horarios de producción, si bien no se han detectado excesos de consumo eléctrico en ese capítulo.

[quote style=”boxed”]Todas estas recomendaciones deben revisarse y adaptarse de forma constante para ajustarlas a la realidad del consumo energético de la empresa. De esta manera, se conseguirá ahorrar electricidad de forma optimizada a los procesos de producción.[/quote]

Descargar recomendaciones completas para ahorrar electricidad de Energy Sentinel para Cevica. Descargar>>

Por último, es importante saber que importantes sellos de certificación como Bureau Veritas o SGS afirman que soluciones como las de Energy Sentinel ayudan de forma importante a la consecución de estos logros, y las recomiendan a la hora de implantar procesos para obterner certificaciones como la 50001. Asimismo, se han demostrado su posicionamiento como instrumentos perfectos para políticas de mejora continua y vigilancia de procesos, que evitan olvidar los buenos hábitos y caer de nuevo en los que producen altos costes.

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