Malaysian factories typically cut electricity costs by 20 to 40% by fixing maximum demand charges, compressed-air leaks, idle machines, motor and fan speeds, and process cooling, then adding rooftop solar. Infinergi measures every major load with Eniscope IoT sub-metering first. At a Johor plant this identified RM 139,622 a month (38%) of avoidable cost.
Where factories lose money on electricity
| Area | Typical problem | Fix |
|---|---|---|
| Maximum demand | Over-declared demand, simultaneous start-ups, peaks during shift changes | Demand review, start-up sequencing, battery peak shaving |
| Compressed air | Leaks, pressure set too high, compressors running at weekends | Leak surveys, pressure reduction, schedules, VSD compressors |
| Motors, pumps & fans | Running at full speed regardless of demand | Variable speed drives, IE3/IE4 motors |
| Process cooling & chillers | Poor sequencing, fixed set-points | Chiller optimisation, set-point reset |
| Idle machines | Machines left on between shifts and over weekends | Smart switches and cloud schedules |
| Office & plant HVAC, lighting | Running outside production hours | Schedules, LED high-bays with sensors |
| Power factor | TNB penalties | Power factor correction |
Case study: RM 1.67M a year at a Johor plant
A Johor manufacturing facility on TNB's E2 tariff was paying RM 366,224 a month. Eniscope monitoring identified RM 139,622 a month (38%) of avoidable cost, about RM 1.67 million a year, including 1,457 kW of over-declared maximum demand, idle equipment and HVAC inefficiency, before any solar was installed.
How we work with manufacturers
- Free TNB bill analysis: tariff, maximum demand, power factor and fuel-adjustment exposure, with savings in RM.
- Eniscope sub-metering on main incomers, compressors, chillers and production lines, installed in hours with no production downtime.
- 2 to 4 weeks of data, then a ranked list of measures with cost, saving and payback.
- Implementation with smart controls, VSDs, compressed-air fixes and demand management.
- Rooftop solar and storage sized to your new, lower load. Industrial systems run from 50 kWp to 5 MWp+.
- Ongoing monitoring and ESG reports for your customers and for EECA 2024.
Solar for factories
Factories have the best solar economics of any segment: large roofs and heavy daytime use. Industrial systems typically offset 40 to 80% of the bill with a 2 to 4-year payback. With a PPA you start with zero capital, and if you buy outright the Green Investment Tax Allowance runs until 31 December 2030. Commercial and industrial solar explained.