Energy Efficiency in the Automotive Industry
The automotive sector is high-stakes, with energy efficiency having evolved from a goal for sustainability into a pillar of operational survival. Manufacturers face the volatile energy costs of the modern day, alongside compulsory Net Zero mandates, meaning industry focus is shifting toward plant efficiency. This addresses both how energy is consumed and how it is sourced.
While traditionally lean manufacturing reduces waste on the factory floor, the most competitive and effective approach is now to tackle the power demands of assembly lines through on-site energy generation.
Utilising solutions including Solar PPAs, automotive manufacturers can disconnect production costs from the instability of the grid, without sacrificing financial investment from other areas of their business. This guide explores how smarter energy sourcing and optimisation are improving energy efficiency in the automotive industry.
Common sources of energy waste
Modern automotive assembly requires a particularly high level of precision consistently, meaning industrial facilities are some of the highest energy-intensive environments in the world. Often, outdated infrastructure, inefficient workflows and lack of optimisation cause large amounts of this energy to be lost as wastage. Identifying these inefficiencies is the first stage in transforming a factory from an energy waste liability into a streamlined and sustainable space.
Paint shop power drain
The paint shop in an automotive factory is notoriously one of the most energy-hungry stages of vehicle manufacturing, with some plants seeing their paint department account for 65% of their CO2 production.
Large amounts of electricity and gas are required to maintain the precise temperature and humidity controls required by paint shops, alongside the power required for high-heat curing ovens. By implementing heat recovery systems, optimising airflow and investing in a self-sufficient energy generation system, manufacturers can reclaim high-cost thermal energy that would otherwise be lost.
Compressed air leaks lead to inefficiency
Compressed air is a key utility in automotive plants, powering everything from pneumatic tools to robotic welding arms. However, compressed air is also one of the biggest hindrances to energy efficiency in the automotive industry, with many systems losing up to 30-40% of their energy to leaks and pressure drops.
Poor insulation
Automotive facilities often operate on a large scale, high-ceilinged warehouse-style buildings which are difficult to heat and cool efficiently, leading to thermal leakage. Inadequate insulation in the roofing and walls forces heating systems to work constantly in order to sustain the temperatures required for assembly of components.
Relinquishing reliance upon the national grid by acquiring a self-sufficient solar PPA alongside improving plant insulation helps to reduce the high costs of heating an automotive plant.
Inefficient lighting
Many automotive plants rely upon inefficient lighting systems which lead to high levels of wastage through heat loss. Smart LED systems which utilise motion sensors consume up to 80% less energy than traditional lighting, which, combined with smart monitoring to optimise usage, results in savings and more efficient energy management.
Automotive energy efficiency with monitoring
Achieving maximum energy efficiency in the automotive industry is impossible without real-time visibility, as you cannot manage what you don’t measure. By utilising Power Zero’s Optimise Portal, manufacturers can go beyond monthly utility bills to identify their spends, instead using accurate and real-time data to analyse when and where energy is being wasted across their production lines.
This precise data allows for optimisation and efficiency, enabling plants to identify and cut down on unnecessary expensive overheads.
Solar PPAs for the automotive industry
A Solar PPA (Power Purchase Agreement) is a strategic solution for automotive manufacturers who are looking to slash energy costs without diverting investment from their core production lines. Under this model, a Power-Zero Solar PPA funds, installs, and maintains a solar array on your facility’s roof at no upfront cost to your business.
Having had the array installed, your business then buys back the electricity generated at a pre-agreed, lower rate than the National Grid, providing you protection against the price volatility seen in the modern day. This allows plant managers to achieve Scope 2 emissions reductions, whilst equally preserving budgets for other areas of the business.
Check out our Solar PPAs for more information on how your business can save money on energy spending
