Sanjeev Jain is a veteran energy expert with 40 plus years of experience in renewable energy and energy efficiency. A former Chief Engineer and Certified Energy Auditor, he currently serves as Vice President at SEEM. His work focuses on translating energy audit insights into real, on-ground impact.
In this conversation with CleanTech Journal, he shares practical insights on energy audits, highlighting what truly drives measurable savings and where industries often miss the mark in execution.
Q1. From your experience, which audit findings deliver the quickest returns? What kind of savings can companies expect?
Energy audit findings broadly fall into two categories. The first includes low investment, behavior driven improvements, and the second involves capital intensive technology upgrades.
The quickest returns usually come from operational and behavioral changes. These include better equipment usage, proper shutdown practices, and stronger maintenance discipline. While these may appear simple, they can deliver immediate savings without requiring capital investment.
Equipment upgrades such as replacing inefficient systems do require investment, but they typically offer a payback period of 2 to 3 years. Many of these are supported through ESCO models, making them financially viable even for cost sensitive industries.
Q2. If budgets are limited, which recommendations should companies prioritize first?
When budgets are limited, companies should start with no cost and low cost measures.
This includes capacity building of plant operators, improving system efficiency, and strengthening operational discipline. These steps can deliver quick results while preparing the organization for larger investments.
Once these improvements are in place, companies can gradually invest in energy efficient technologies in a phased manner, ensuring that each step delivers measurable returns.
Q3. Many audit recommendations look good on paper but fail in execution. What are the most common gaps?
The most common gap comes from the difference between audit assumptions and actual operating conditions.
Audits are usually based on past data and controlled assessments. However, during implementation, variations in processes, system compatibility, and operational practices can affect the results.
Another challenge is adapting technology to existing systems. Even though most recommended solutions are mature and proven, successful implementation requires alignment with real world conditions and time for stabilization.
Q4. Which industries benefit the most from energy audits and who is still underutilizing them?
Almost all industries benefit from energy audits, but the highest untapped potential lies in MSMEs.
MSMEs often operate in less structured environments, with limited awareness of advanced technologies and restricted access to funding. Despite contributing significantly to the economy, they still underutilize energy efficiency practices.
Government initiatives are increasingly focused on supporting MSMEs through awareness programs, capacity building, and financial assistance to accelerate adoption.
Q5. Have there been any notable technological innovations in energy efficiency?
There have been several impactful innovations in recent years.
One example is the direct rolling process used in steel rolling mills. This process eliminates the need for reheating raw materials, reducing energy consumption significantly.
Another key innovation is waste heat recovery systems. These systems capture excess heat generated in industrial processes and convert it into usable energy, often even generating power. Industries such as steel and cement have already adopted these solutions at scale.
Q6. What are some quick wins companies can implement immediately without major investment?
The most effective quick wins come from people and processes rather than technology.
Organizations should focus on building awareness and accountability across all levels, from management to plant operators. Energy efficiency should be treated as a shared responsibility across the organization.
Simple improvements in monitoring, operating practices, and decision making can collectively reduce energy consumption without requiring significant investment.
Closing Note
