Despite energy-related financial concerns and the growing demand for sustainability, many energy efficiency measures are not being implemented in industrial practice. There are a number of reasons for this, including a lack of knowledge about energy efficiency potentials and the assessment of energy savings as well as the high workloads of employees. This article describes the systematic development of an expert system, which offers a chance to overcome these obstacles and contribute significantly to increasing the energy efficiency of production machines. The system employs data-driven regression models to identify inefficient parameter settings, calculate achievable energy savings, and prioritize actions based on a fuzzy rule base. Proposed measures are first applied to an analytical real-time simulation model of a production machine to verify that the constraints required for the specified product quality are met. This provides the machine operator with the expert means to apply proposed energy efficiency measures to the physical entity. We demonstrate the development and application of the system for a throughput parts-cleaning machine in the metalworking industry.

To reduce global greenhouse gas emissions, numerous new renewable power plants are installed and integrated in the power grid. Due to the volatile generation of renewable power plants large storage capacity has to be installed and electrical consumer must adapt to periods with more or less electrical generation. Industry, as one of the largest global consumers of electrical energy, can help by adjusting its electricity consumption to renewable production (demand response). Industrial aqueous parts cleaning machines offer a great potential for demand response as they often have inherent energy storage potential and their process can be adapted for energy-flexible operation. Therefore, this paper presents a method for implementing demand response measures to aqueous parts cleaning machines. We first determine the potential for shifting electrical consumption. Then, we adapt the automation program of the machine so that submodules and process steps with high potential can be energy-flexibly controlled. We apply the method to an aqueous parts cleaning machine in batch process at the ETA Research Factory.

Despite energy-related financial concerns and the growing demand for sustainability, many energy efficiency measures are not being implemented in industrial practice. There are a number of reasons for this, including a lack of knowledge about energy efficiency potentials and the assessment of energy savings as well as the high workloads of employees. This article describes the systematic development of an expert system, which offers a chance to overcome these obstacles and contribute significantly to increasing the energy efficiency of production machines. The system employs data-driven regression models to identify inefficient parameter settings, calculate achievable energy savings, and prioritize actions based on a fuzzy rule base. Proposed measures are first applied to an analytical real-time simulation model of a production machine to verify that constraints required for the specified product quality are met. This provides the machine operator with the expert means to apply proposed energy efficiency measures to the physical entity. We demonstrate the development and application of the system for a throughput parts cleaning machine in the metalworking industry.

The German industrial and energy sectors accounted for over 52% of national greenhouse gas emissions in 2024. This is influenced both by an ongoing demand for fossil fuels and the usage of emission-intensive raw and processed materials. With the current European directive on corporate sustainability reporting, a push is being made for companies to publish annual emission reports. However, as per a study conducted by the authors, small and medium-sized companies have difficulties accurately calculating emissions across their supply chain without relying on external service providers. As a scientific institute with a real production facility for metal machining, the ETA (Energy Technologies and Applications) Factory bridges the gap between academia and manufacturing enterprises. The authors have used this disposition to calculate scope 1–3 emissions for the factory as per the Greenhouse Gas Protocol across three years, while progressively attempting to automate data collection for all scopes. CO₂e emissions for the years 2022–2024 were 86.3 tCO₂e, 146.9 tCO₂e, and 86.1 tCO₂e, respectively. Emission categories were assessed in terms of relevance to the institute and subsequently used to analyze the emission activities of the factory. The highest contributor to emissions was electricity purchasing for 2022 and 2024, along with business travel for 2023. Within scope 3, the emissions produced by business travel showed the highest impact across all years, followed by either energy-related activities or purchased goods. The sensitivity of CO₂e factors was also investigated, showing discrepancies between 25% and 130% for the utilized CO₂e factor for steel. Automation of data collection benefits largely from implemented manufacturing systems, such as manufacturing execution systems or enterprise resource planning systems.

The importance of parts cleaning and drying in the metal cutting industry is increasing due to higher quality requirements. At the same time, rising energy prices and climate policy goals create increasing incentives to reduce energy consumption. This study quantifies savings potentials in the use of infrared radiators and inductors in industrial parts drying. The performed experiments illustrate that alternative drying technologies enable a reduction in energy consumption up to 65 %.