Manufacturing Modernization Insights from the Manufacturers’ Council of the Inland Empire
Summer has a way of reminding manufacturers that energy isn’t just another utility bill—it’s a competitive advantage.
As temperatures climb, air compressors work harder, cooling systems run longer, and motors draw more power. For many manufacturers, every degree on the thermometer is reflected somewhere on the monthly electric bill.
Yet while energy prices remain a growing concern, many manufacturers are finding significant savings by modernizing the way their facilities use energy rather than simply using less of it.
The U.S. Department of Energy’s Better Plants program provides a compelling example. More than 315 manufacturing partners, representing approximately 14% of America’s manufacturing footprint, have collectively saved more than $15.2 billion in energy costs while improving competitiveness through better energy management. Participating manufacturers commit to reducing their energy intensity by 25% over ten years, supported by technical expertise and proven best practices.
The lesson isn’t that every manufacturer will reduce energy use by exactly 25 percent.
The lesson is that many plants still have untapped opportunities.
For some manufacturers, the biggest opportunity may be an aging compressed air system. The Department of Energy notes that more than 80% of the energy used to produce compressed air is ultimately lost as heat, making compressed air one of the least efficient utilities in many facilities. Even relatively simple improvements—repairing leaks, improving controls, or reducing unnecessary compressed air use—can generate meaningful savings while improving reliability.
For others, the opportunity lies in motors. Electric motors account for approximately 54% of industrial electricity consumption in U.S. manufacturing, powering everything from pumps and conveyors to compressors, mixers, grinders, and material handling systems. Improving motor efficiency, variable-speed drives, or the systems those motors support can reduce operating costs while extending equipment life.
Modernization isn’t limited to equipment replacement, either.
Many manufacturers are realizing measurable gains through improved controls, building automation, LED lighting, HVAC optimization, production scheduling, renewable energy integration, and real-time energy monitoring. In many cases, these improvements also reduce maintenance costs, improve uptime, and create a more comfortable working environment for employees.
The challenge is knowing where to begin.
Every facility is different. An investment that delivers an outstanding return in one plant may offer only modest benefits in another. That’s why successful manufacturers typically begin with an assessment—not a purchase order.
Through the Manufacturing Modernization Assessment (MMA) program, the Manufacturers’ Council of the Inland Empire helps manufacturers identify practical opportunities to improve energy efficiency, reduce operating costs, strengthen productivity, and evaluate modernization opportunities across the entire operation. Every assessment is confidential, tailored to the individual facility, and provided at no cost through grant funding secured by MCIE exclusively for manufacturers in Riverside and San Bernardino counties.
With summer temperatures climbing and energy costs continuing to pressure margins, there may be no better time to ask a simple question:
Is your equipment working as efficiently as your people?
To learn more or schedule a brief introductory consultation, contact Sandra Sisco at ssisco@mfgcouncilie.com.
