Manufacturers Lose Up To 15% Energy To Poor Maintenance – MAN

Manufacturers Association of Nigeria has disclosed that weak maintenance practices are costing factories between 10 and 15 per cent of their energy use, while the absence of monitoring systems is preventing firms from tracking and managing consumption efficiently.

The findings emerged from a Cleaner Production Assessment conducted across 42 manufacturing facilities in four geopolitical zones. The study, which examined sectors ranging from food processing and metals to textiles, wood products and petrochemicals, revealed widespread inefficiencies in industrial energy use.

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Technical experts presenting the report said a major gap exists between current operational practices and global efficiency benchmarks, noting that while a handful of firms have adopted modern energy management systems, many others lag behind.

The assessment identified compressed air systems as one of the largest sources of power waste, accounting for roughly a quarter of electricity losses in factories due to leaks, overuse, and poor system calibration. In several plants, optimisation efforts were sufficient to allow operators to shut down an entire compressor.

Steam generation systems were responsible for about 30 per cent of losses, while inefficient lighting contributed another 18 per cent. Additional inefficiencies were traced to poor insulation in boilers and furnaces, heat losses through flue gases, motors running below optimal loads, and the limited adoption of Variable Speed Drives.

A major structural challenge identified in the study was the absence of sub-metering in most facilities, which makes it difficult for operators to track how much energy different processes consume. Without accurate measurement, experts noted, effective management becomes nearly impossible.

Idle machinery in some textile and leather factories was also cited as a contributor to avoidable losses, reinforcing the conclusion that maintenance culture plays a central role in energy performance.

Regional disparities were observed, with unreliable grid supply in northern and eastern industrial hubs worsening inefficiencies, while thermal losses were more pronounced in heavy industrial sectors such as metals and petrochemicals.

Despite these challenges, the study highlighted examples of improvement, including a Lagos-based food processing plant that reduced compressed air leakages by 20 per cent following system optimisation.

Overall, the assessment estimated that factories could cut energy use by between 20 and 25 per cent if structured efficiency measures were adopted, potentially saving up to 500 megawatt-hours annually per facility.

Industry stakeholders were urged to adopt internationally recognised management standards, particularly ISO 50001 for energy systems and ISO 14001 for environmental and resource efficiency, as tools for institutionalising best practices.

Project coordinators involved in the initiative also raised concerns about water usage, noting that many factories rely heavily on borehole supply without measuring consumption or recycling wastewater. They argued that improved monitoring and reuse systems could significantly reduce resource costs and environmental impact.

Experts stressed that leadership commitment remains the decisive factor in driving efficiency improvements. Without management buy-in, they warned, technical staff alone cannot implement the changes required to reduce waste and costs.

Industry leaders noted that efficiency gains go beyond cost reduction, adding that lowering energy consumption improves competitiveness, reduces emissions, and strengthens long-term sustainability for manufacturers operating in a challenging economic environment.