5 Ways to Reduce Energy Consumption in Your Temperature Control System

Energy Costs Are the Biggest TCU Expense – After the Purchase

The purchase price of a Temperature Control Unit represents only a fraction of its total cost of ownership. Over a typical 20-30 year lifespan, energy consumption accounts for the majority of operating costs. Even modest improvements in energy efficiency can translate to significant savings. Here are five practical measures that deliver real results.

1. Right-Size Your TCU

An oversized TCU wastes energy on every cycle. If your unit has 36 kW of heating capacity but your process only requires 18 kW, you are paying for capacity you do not use – and the larger pumps and heaters consume more energy even at partial load.

Conduct a thermal audit of your actual process requirements. Measure your real heat loads during production, not just during start-up. Many operations discover that their TCUs are significantly oversized because the original specification included excessive safety margins or was based on worst-case scenarios that never occur in practice.

If replacing an oversized unit is not immediately feasible, consider whether pump speed reduction (via VFD) can reduce energy waste without affecting process performance.

2. Use Variable Frequency Drive (VFD) Pumps

Traditional TCUs run their circulation pumps at full speed continuously, regardless of actual flow requirements. A variable frequency drive adjusts pump speed to match actual demand, following the affinity laws where power consumption drops with the cube of speed reduction.

In practical terms, reducing pump speed by just 20% can cut pump energy consumption by nearly 50%. For processes with variable heat loads – which includes most batch processes and many injection moulding operations – VFD pumps deliver energy savings of 20-40% compared to fixed-speed alternatives.

Boe-Therm's TEMP 90VFD is specifically designed with integrated variable frequency drive technology, making it the most energy-efficient option for applications up to 90°C.

3. Optimise Your Cooling Strategy

Cooling is often where the most energy is wasted. Key improvements include ensuring your cooling water supply temperature is as low as practically achievable, using free cooling (cooling towers or dry coolers) instead of mechanical refrigeration when ambient conditions allow, checking that cooling valves are properly calibrated and not hunting (constantly opening and closing), and considering indirect cooling with a properly sized heat exchanger – an undersized exchanger forces the system to work harder.

Also review whether your cooling water flow rates are appropriate. Excessive flow wastes pump energy; insufficient flow reduces heat transfer effectiveness and can cause temperature instability.

4. Maintain Your Equipment

A poorly maintained TCU can consume 15-30% more energy than an identical well-maintained unit. The main culprits are scale buildup in heat exchangers and process circuits, which acts as insulation and reduces heat transfer. Degraded thermal oil (in oil systems) has reduced heat transfer capacity. Worn pump impellers reduce flow efficiency. Faulty temperature sensors cause the controller to overshoot or hunt around setpoint.

Implement a preventive maintenance schedule that includes regular water quality testing and treatment, annual heat exchanger inspection and cleaning, thermal oil analysis and replacement when degradation indicators are reached, and calibration checks on temperature sensors and controllers.

5. Insulate and Eliminate Heat Losses

Uninsulated pipes, tanks, and TCU components radiate heat into the production environment – energy that was paid for but adds no value to the process. In high-temperature applications (above 100°C), heat losses from uninsulated surfaces can be substantial.

Insulate all process piping between the TCU and the point of use. Check that TCU cabinet insulation is intact and not damaged. Ensure hose connections are properly insulated, especially on oil systems where surface temperatures can exceed 200°C. Consider the ambient environment: if your TCU is located in a cold area, more heat is lost to the surroundings.

Calculate Your Savings Potential

Even implementing two or three of these measures typically reduces total TCU energy consumption by 15-25%. On a unit running 6,000 hours per year with a 20 kW average power draw, a 20% reduction saves approximately 24,000 kWh annually – a meaningful reduction in both cost and carbon footprint.

Boe-Therm's technical team can conduct an energy assessment of your current temperature control setup and recommend specific improvements based on your actual operating conditions. Contact us to discuss how to optimise your system's energy performance.