Volatility in global energy markets and hourly changes in electricity tariffs in Turkey have transformed energy management for industrial facilities from a mere cost item into a strategic operational necessity. Today, factories seeking a competitive advantage are moving away from traditional fixed-shift patterns and redesigning their production processes and utility plant operations with an "hourly consumption profile" focused approach. Synchronizing the demand on the production line with Day-Ahead Market (GÖP - Gün Öncesi Piyasası) prices managed by EPİAŞ (Enerji Piyasaları İşletme A.Ş. - Energy Exchange Istanbul) both reduces direct energy costs and facilitates compliance with international regulations such as the Carbon Border Adjustment Mechanism (CBAM).

Data Collection and Monitoring: The Cornerstone of Optimization

The first step for a facility to optimize its consumption profile is to create a digital twin of the current situation using high-resolution data. The data collection process should cover not only main meter values but also the instantaneous tracking of energy-intensive processes in sub-breakdowns.

OSOS and Analyzer Integration

Automatic Meter Reading Systems (OSOS - Otomatik Sayaç Okuma Sistemleri) allow the facility to track the energy drawn from the grid according to legal standards. However, for true optimization, one must go beyond the main inlet and place energy analyzers on critical machine groups and utility plants (compressors, cooling towers, boilers). The 15-minute or hourly data received through these analyzers reveals the facility's characteristic "energy signature."

Data Cleaning and Profiling

Collected data must be correlated with production volumes, outdoor temperatures, and shift patterns. For example, when calculating specific energy consumption (SEC), the base load (energy consumed when there is no production) and the variable load (energy dependent on production) should be separated. This distinction is critical for understanding which processes are suitable for "load shifting."

Production Planning and Shift Optimization

Energy costs in industry are generally shaped by three-time tariffs—daytime, peak, and night—or hourly prices within the scope of the last resort supply tariff. Flexing production planning according to these hours directly affects the unit cost.

Load Shifting Strategies

The most fundamental optimization step is shifting the operating hours of energy-intensive machines (e.g., arc furnaces, large extruder lines, or heat treatment furnaces) from peak hours when electricity unit prices are highest (usually between 17:00 - 22:00) to lower-cost hours. What needs to be considered in this process is creating "production buffers" without compromising delivery times.

Redesigning Shift Timing

Instead of traditional 08:00-16:00, 16:00-00:00, and 00:00-08:00 shifts, flexible shift models centered on hours when energy prices bottom out can be implemented. Especially in facilities with Solar Power Plants (GES - Güneş Enerji Santrali) for self-consumption, planning energy-intensive tasks during noon hours when production is at its highest minimizes expensive energy drawn from the grid.

Hourly Management of Utility Plants

Utility plants (compressed air, cooling, steam), which are often overlooked but account for 30% to 50% of total energy consumption, are the areas offering the highest flexibility for optimization.

  • Compressed Air Systems: Reducing compressor idling times and using tank capacities to store air during cheap energy hours and use this air during peak hours.
  • Chillers and Cooling Groups: Meeting daytime cooling needs by producing ice or cold water at night using thermal storage solutions.
  • Lighting and HVAC: Making automatic curtailments based on hourly occupancy rates via smart building management systems.

Example Scenario: Plastic Injection Factory

Suppose a plastic injection factory pauses raw material drying and molding processes between 18:00 - 21:00, when hourly electricity prices rise, and allocates this time to machine maintenance and cleaning. With just this 3-hour "load shifting" operation, the facility can achieve savings of 8% to 12% on its monthly energy bill. Additionally, through analyses performed on platforms like etta, it was determined that 15% of the factory's base load originated from unused office devices, and this loss was eliminated with automatic shutdown protocols.

Regulations and Sustainability Reporting

These optimizations made on an hourly basis are not just about cost. Energy management compatible with EPDK (Enerji Piyasası Düzenleme Kurumu - Energy Market Regulatory Authority) and EPİAŞ data also reduces the facility's carbon intensity. Within the scope of the European Green Deal, reporting carbon emissions per product (CSRD - Corporate Sustainability Reporting Directive) is becoming mandatory. Manufacturing during hours when energy is cleanest (high renewable share) directly contributes to the "green certification" of products.

Frequently Asked Questions

Does changing the production profile create operational risk?

Not when planned correctly. Optimization changes only the timing of processes based on data, without jeopardizing production targets. Critical orders always take priority.

Are these analyses meaningful for small-scale facilities as well?

Absolutely. For any business where energy costs account for more than 10% of total expenses, hourly profile analysis provides an efficiency increase that requires no investment.

What role do platforms like etta play in this process?

etta transforms complex OSOS and analyzer data into meaningful dashboards, showing which process creates how much cost at what hour. With AI-supported forecasting models, it suggests the most ideal production plan according to tomorrow's energy prices.

Does load shifting increase labor costs?

If shift hours change radically, overtime pay may be affected. However, generally, utility plant optimization and short-term in-process adjustments provide energy savings without changing labor costs.