Industries lose 15% energy to weak maintenance – MAN

The Manufacturers Association of Nigeria has found that maintenance lapses account for between 10 and 15 per cent of energy waste in factories, while most facilities lack sub-metering systems needed to track consumption.

The findings emerged from a Cleaner Production Assessment conducted in 42 industries across four geopolitical zones and presented at the National Stakeholders’ Sensitisation Workshop on ISO 50001 and 14001 standards in Lagos on Tuesday.

The assessment, carried out under the GEF-UNIDO Industrial Energy Efficiency and Resource Efficiency Cleaner Production Project, covered sectors including food and beverages, basic metals, wood and wood products, textiles and leather, and petrochemicals.

Presenting the technical findings, IEE and RECP National Expert Obafemi Adejumo said the study exposed a wide gap between current practices and global best standards. He noted that the study uncovered significant industrial energy efficiency gaps across the country.

“What I have noticed is that there is a big gap between where we should be and where we are at the moment. Not all parts of the industry are doing well with energy efficiency. Some industries are already doing well, but a lot of other industries have not really plugged into it”, Adejumo said.

The CPA identified compressed air systems as a major source of electricity waste, accounting for about 25 per cent of losses, largely due to leaks and improper use. In some plants, optimising the system enabled operators to shut down one compressor entirely.

Steam systems accounted for 30 per cent of losses, while lighting contributed 18 per cent. The assessment also found significant thermal losses from poor insulation and flue gases in boilers and furnaces, inefficient motor systems running at partial loads, and a lack of Variable Speed Drives.