How to Reduce Energy Consumption in Aluminium Extrusion Plants
Published by: ALUTimes | Date: July 15, 2025
Table of Contents
- Introduction
- Why Energy Efficiency Matters
- High-Energy Areas in Extrusion
- Top Strategies to Reduce Energy Usage
- Case Study: Energy Savings in Action
- Smart Tech & IoT for Monitoring
- Sustainability & Compliance
- Conclusion
- Disclaimer
Introduction
Energy consumption is one of the largest operational costs in aluminium extrusion. From billet heating to profile cooling, power usage can significantly impact plant profitability and sustainability. With rising energy costs and environmental regulations, reducing energy usage is now a priority for every aluminium extrusion facility in 2025.
Why Energy Efficiency Matters in Aluminium Extrusion
- Cost Savings: Lower energy bills mean improved profit margins.
- Environmental Impact: Reducing carbon emissions aligns with global sustainability goals.
- Government Incentives: Many governments now offer tax benefits for energy-efficient operations.
- Competitive Advantage: Energy-smart operations win more tenders and green certifications.
Major Areas of Energy Consumption in Extrusion Plants
1. Billet Preheating: The billet oven can consume up to 30–40% of the total plant energy.
2. Extrusion Press: Hydraulic systems and motors are major contributors.
3. Aging Ovens: Post-extrusion heat treatments are energy intensive.
4. Compressed Air Systems: Often overused or under-maintained.
Top Strategies to Reduce Energy Usage
Upgrade to Energy-Efficient Motors and Drives
Replacing outdated motors with IE3 or IE4-rated efficiency models can reduce power draw by up to 15%.
Implement Heat Recovery Systems
Heat from ovens and furnaces can be captured and reused to preheat billets or warm factory air, saving fuel costs.
Optimize Billet Heating Cycles
- Use billet temperature monitoring systems to avoid overheating
- Switch to gas-electric hybrid ovens for better control
Maintain and Audit Compressed Air Systems
Leaks in compressed air systems can waste up to 30% of energy. Perform leak detection checks quarterly.
Install Variable Frequency Drives (VFDs)
VFDs on hydraulic and cooling systems allow motors to run only when needed, avoiding idle consumption.
Switch to LED Lighting
Simple but effective—LEDs consume up to 80% less power and last longer than conventional lighting.
Train Staff on Energy Awareness
Operational behavior plays a role. Conduct regular energy workshops to encourage best practices.
Case Study: Energy Savings in an Indian Extrusion Plant
An aluminium extrusion facility in Gujarat implemented the following:
- Replaced 15 motors with high-efficiency alternatives
- Installed furnace heat recovery systems
- Digitized air compressor systems
- Trained operators in energy best practices
Result: 28% drop in energy consumption over 12 months, translating into ₹1.2 crore annual savings.
Smart Technologies & IoT for Energy Monitoring
Smart meters and IoT platforms can track energy consumption in real-time across machines and shifts. Predictive analytics helps schedule maintenance and avoid downtime.
Tools to Explore:
- Siemens Energy Manager Pro
- Rockwell FactoryTalk Energy
- ABB Ability Smart Sensors
Aligning Energy Efficiency with Sustainability Goals
Reducing energy use contributes to ESG (Environmental, Social, and Governance) goals, a key factor for investors in 2025. Extrusion plants with strong ESG scores often receive preferential project approvals and funding.
Conclusion
Reducing energy consumption in aluminium extrusion plants is both an economic and environmental imperative. Through targeted upgrades, smart tech, and continuous improvement, companies can significantly reduce their energy footprint while improving profitability. Start small with audits and training, and gradually implement smarter systems for long-term success.
Disclaimer
This content is published by ALUTimes for informational purposes only. Specific results may vary by plant size and operational practices. Always consult a certified energy consultant before making major capital investments.