Sustainable Manufacturing Energy Management Training Course

Duration 10 days 16 modules · 65 contact hours
Level Intermediate Certificate on completion
Who attends Energy Managers, Manufacturing Engineers and others
Fee from USD 2,200 KSh 190,000 for Kenyan organisations
Where 52 cities + online See dates by city
Next start 16 Nov 2026 Course code SD-ETR-029

Before you join: Participants should have practical familiarity with manufacturing operations, plant utilities, facilities management, engineering, sustainability reporting or capital projects.

Dates & prices

Two start dates a month in every city, and live online on weekdays or weekends. Fees are per participant; classroom fees include tuition, materials, lunch and refreshments, and the certificate.

Suggest a date or city

Showing the next six months. Later dates, other cities and private deliveries for your team are available on request.

Course overview

Manufacturers face energy costs, carbon reporting obligations, reliability risks and customer pressure to demonstrate lower-emission production. The practical challenge is not simply selecting renewable technologies; it is finding the energy losses that matter, establishing credible baselines, prioritising projects, securing operational ownership and proving savings after implementation. Poorly specified energy projects can disrupt production, miss expected savings or create unmanageable maintenance demands.

This course equips participants to manage industrial energy as a measurable operating cost, emissions source and capital-planning issue. Participants work through ISO 50001 energy management requirements, energy review methods, metering strategies, production-normalised energy performance indicators, load profiling, demand management, compressed-air improvement, heat recovery, electrification and renewable-energy procurement. They assess technical and financial options using life-cycle cost analysis, net present value, marginal abatement cost curves and measurement and verification plans based on IPMVP.

Teaching combines concise technical briefings with manufacturing cases, data interpretation, group decision exercises, supplier-proposal reviews and structured application planning. Cases reflect facilities such as food processing plants, cement works, pharmaceutical manufacturing, textiles operations and industrial assembly sites. Participants progressively build an energy management case for a selected manufacturing facility, from baseline and opportunity register through to investment recommendation, implementation controls and verified savings plan. They leave with reusable templates and a completed energy transition project pack suited to discussion with operations, finance, engineering and senior management.

The course is intended for professionals who already work with manufacturing operations, utilities, facilities, sustainability, maintenance or capital projects and need to convert energy ambition into disciplined operational action.

What you will be able to do

  • Conduct an ISO 50001-aligned energy review using utility, production and equipment data
  • Calculate production-normalised energy performance indicators and identify material energy uses
  • Develop a metering and submetering plan for actionable manufacturing energy data
  • Evaluate efficiency, electrification, heat recovery and renewable options using life-cycle cost analysis
  • Prepare an energy project business case using NPV, IRR, payback and sensitivity analysis
  • Design an IPMVP measurement and verification plan for energy-saving projects
  • Build a phased decarbonisation roadmap linked to production, maintenance and capital plans
  • Present a complete manufacturing energy management and transition project pack

Benefits of attending

For you

  • Build confidence discussing energy projects with operations, finance and engineering leaders
  • Produce defensible energy-saving estimates rather than relying on supplier claims
  • Assess renewable and electrification proposals against production and reliability constraints
  • Apply recognised measurement and verification methods to prove project results
  • Create a portfolio-quality manufacturing energy transition project pack

For your organisation

  • Improves prioritisation of energy projects using operational and financial evidence
  • Reduces avoidable utility costs through targeted management of significant energy uses
  • Strengthens governance for energy baselines, performance indicators and savings claims
  • Supports credible capital planning for efficiency, electrification and renewable investments
  • Connects site-level energy action with emissions targets and production plans

Course modules

16 modules over 10 days

Participants can frame energy management as an operational, financial and emissions-management discipline.

  • Energy cost, reliability and emissions drivers within manufacturing operating models
  • Significant energy uses identified through Pareto analysis and process mapping
  • Energy intensity distinguished from total consumption using production-normalised measures
  • Operational boundaries defined for plants, utilities and supporting infrastructure
  • Energy management roles assigned using RACI responsibility matrices
  • Improvement portfolios linked to throughput, quality, maintenance and safety priorities

Participants can apply ISO 50001 requirements to structure a site energy management system.

  • ISO 50001 clauses interpreted for manufacturing energy planning and control
  • Energy policy commitments translated into measurable site-level objectives
  • Plan-Do-Check-Act cycle applied to energy performance improvement
  • Legal and customer requirements recorded within compliance obligation registers
  • Documented information controlled for energy procedures, records and evidence
  • Management review inputs prepared from performance, risks and improvement actions

Participants can build defensible energy baselines and performance indicators from plant data.

  • Utility invoices reconciled with meter reads and production records
  • Baseline periods selected using representative operating and weather conditions
  • EnPIs calculated as kilowatt-hours per tonne, unit or batch
  • Regression analysis separates production, weather and fixed-load energy drivers
  • CUSUM charts reveal persistent changes against expected energy consumption
  • Data-quality checks identify missing intervals, meter errors and outliers

Participants can specify a metering architecture that supports operational energy decisions.

  • Meter hierarchy designed from incoming supply to significant energy uses
  • Submeter locations prioritised using materiality, controllability and data gaps
  • Interval data requirements matched to load, tariff and process behaviour
  • Measurement accuracy assessed through meter classes and calibration records
  • Energy dashboards structured around alarms, trends and accountability meetings
  • Data acquisition protocols define ownership, validation and retention requirements

Participants can identify tariff exposure and demand-management opportunities from load data.

  • Half-hourly load profiles interpreted against production schedules and tariffs
  • Maximum demand charges analysed using peak coincidence and load duration curves
  • Demand response options assessed for process flexibility and product constraints
  • Power factor correction evaluated alongside harmonics and electrical reliability
  • Tariff structures compared using time-of-use and capacity charge models
  • Peak-shaving controls sequenced around compressors, chillers and batch processes

Participants can conduct a structured industrial energy audit and prioritise findings.

  • Walkthrough audit plans target significant energy uses and operating losses
  • Process flow diagrams connect energy inputs, utilities and product outputs
  • Opportunity registers capture assumptions, owners, savings and implementation barriers
  • Root-cause analysis distinguishes equipment faults from operating practice failures
  • FMEA identifies energy-project risks affecting safety, quality and uptime
  • Prioritisation matrices rank opportunities by impact, effort and operational risk

Participants can identify and appraise energy improvements in motor-driven utility systems.

  • Motor system losses assessed through load factor and efficiency classes
  • Variable speed drives screened against throttle, damper and bypass control
  • Compressed-air leaks quantified using ultrasonic surveys and demand estimates
  • System pressure setpoints reviewed against end-use equipment requirements
  • Compressor sequencing optimised through base-load and trim-control strategies
  • Specific energy consumption tracked in kilowatt-hours per cubic metre

Participants can evaluate thermal efficiency and heat-recovery opportunities within process systems.

  • Steam balance diagrams trace generation, distribution, use and condensate return
  • Boiler efficiency calculated using direct and indirect heat-loss methods
  • Steam traps surveyed using temperature, ultrasound and failure categorisation
  • Pinch analysis identifies heat recovery targets between process streams
  • Waste heat sources screened by temperature, availability and contamination risk
  • Condensate recovery valued through fuel, water and treatment cost savings

Participants can integrate energy performance into process-control and production-improvement decisions.

  • Statistical process control links energy variation with process stability
  • Standard operating procedures embed energy setpoints and shutdown routines
  • Overall equipment effectiveness examined alongside energy intensity indicators
  • Batch scheduling reduces idle loads, warm-up losses and peak demand
  • Control charts distinguish normal energy variation from special causes
  • Operator engagement plans connect daily actions with measurable energy outcomes

Participants can assess electrification options for industrial heat and process equipment.

  • Process heat demand classified by temperature range and duty profile
  • Electric boilers compared with fossil boilers using operating cost scenarios
  • Industrial heat pumps screened using source temperatures and coefficient performance
  • Resistance heating applications assessed for controllability and power infrastructure
  • Grid capacity constraints evaluated through connection studies and demand forecasts
  • Electrification sequencing considers equipment replacement cycles and production continuity

Participants can assess on-site renewable generation and storage for manufacturing facilities.

  • Solar photovoltaic yield estimated from irradiation, shading and roof constraints
  • Behind-the-meter generation matched with daytime load and export arrangements
  • Battery storage cases tested for demand charges, resilience and arbitrage
  • Wind resource screening considers site conditions, permitting and grid connection
  • Interconnection requirements reviewed with protection studies and utility approvals
  • Renewable asset operations planned through performance monitoring and maintenance contracts

Participants can compare renewable-energy procurement routes and assess associated emissions claims.

  • Power purchase agreements compared with green tariffs and certificates
  • On-site ownership assessed against lease, service and shared-savings structures
  • GHG Protocol Scope 2 accounting distinguishes location-based and market-based methods
  • Renewable certificate quality reviewed through vintage, geography and exclusivity criteria
  • Contract risks assessed for volume, price, curtailment and credit exposure
  • Procurement approval papers align energy strategy, treasury and legal requirements

Participants can prepare financially credible business cases for energy and decarbonisation projects.

  • Life-cycle cost analysis captures capital, energy, maintenance and replacement costs
  • Net present value calculated using cash flows and approved discount rates
  • Internal rate of return compared with corporate hurdle-rate requirements
  • Sensitivity analysis tests energy prices, production volumes and performance assumptions
  • Marginal abatement cost curves rank projects by cost and emissions reduction
  • Business cases quantify downtime, reliability and non-energy operational benefits

Participants can design credible savings measurement and verification plans for implementation projects.

  • IPMVP options selected according to project scope and measurement boundaries
  • Measurement and verification plans define variables, periods and adjustment methods
  • Baseline adjustments document production, weather and operating-condition changes
  • Savings reports distinguish avoided consumption from metered renewable generation
  • Confidence intervals communicate uncertainty within reported project results
  • Energy performance reviews trigger corrective action and management escalation

Participants can build a governed implementation roadmap for manufacturing energy transition projects.

  • Project charters define scope, benefits, owners and decision rights
  • Stage-gate governance controls feasibility, procurement, installation and handover decisions
  • Critical path schedules coordinate shutdown windows, contractors and commissioning
  • Change-management plans address operator adoption and revised maintenance routines
  • Risk registers track safety, supply-chain, permitting and performance threats
  • Decarbonisation roadmaps sequence quick wins, renewals and strategic investments

Participants can build, review and present a complete energy management and transition project pack for a manufacturing facility.

  • Energy baseline and significant energy uses consolidated into decision-ready analysis
  • Opportunity portfolio prioritised using savings, emissions, cost and implementation criteria
  • Selected interventions tested against production, reliability and maintenance constraints
  • Financial model presents NPV, payback, sensitivity and funding assumptions
  • IPMVP plan defines data collection, baseline adjustments and savings reporting
  • Implementation roadmap assigns milestones, governance controls and accountable owners

Exercises and examples are adapted to each cohort's sectors and roles.

What you take back to work

  1. ISO 50001 energy review template
  2. Manufacturing energy baseline and EnPI model
  3. Submetering and energy monitoring plan
  4. Industrial energy opportunity register
  5. Energy project financial appraisal model
  6. Manufacturing energy transition project pack

Who should attend

  • Energy Managers — responsible for energy performance, utility spend and improvement programmes
  • Manufacturing Engineers — need to reduce energy intensity without compromising throughput
  • Facilities Managers — manage site utilities, building services and energy infrastructure
  • Sustainability Managers — translate emissions commitments into site-level energy actions
  • Maintenance Managers — prioritise reliability and maintenance implications of energy projects
  • Capital Project Managers — assess energy investments, renewable assets and implementation risks

Skills and tools covered

Energy baseline analysisIndustrial load profilingEnergy project appraisalRenewable energy procurementSavings measurement verificationDecarbonisation roadmapping

Tools and standards

ISO 50001, ISO 50006, IPMVP, GHG Protocol Scope 2 Guidance

How the course runs

Training methodology

The course uses short technical briefings followed by manufacturing cases, data reviews, group analysis and decision simulations. Participants interpret utility and production data, diagnose energy losses, compare project proposals and prepare investment recommendations. Instructor feedback focuses on assumptions, operational constraints, financial logic and evidence for savings claims. Application planning is threaded through both weeks, enabling participants to adapt templates to their own facilities. The final capstone brings the methods together in a reviewed presentation to a simulated investment and operations panel.

Requirements and prerequisites

Participants should have practical familiarity with manufacturing operations, plant utilities, facilities management, engineering, sustainability reporting or capital projects. They should be comfortable reading basic energy bills, production data and simple spreadsheet calculations. Prior experience with energy audits, ISO 50001, renewable-energy procurement or carbon accounting is useful but not required. The course does not assume advanced electrical engineering, process design, financial modelling or specialist simulation software knowledge. Participants will benefit most by bringing a real facility, production line or energy project they can use as a reference case.

A typical training day

08:30 – 10:30First session
10:30 – 10:45Refreshment break
10:45 – 12:30Second session
12:30 – 13:30Lunch and networking
13:30 – 15:00Third session
15:00 – 15:15Refreshment break
15:15 – 16:30Workshop and daily review

Live online deliveries follow the same structure in East Africa Time, with shorter screen blocks and longer breaks.

What the fee includes

  • Instruction by a practitioner facilitator
  • Full course workbook and materials
  • Exercise files, templates and case studies
  • Refreshments and lunch on classroom deliveries
  • Certificate of completion
  • Post-course application plan

Frequently asked questions

Participants need familiarity with manufacturing operations, utilities, facilities, engineering, sustainability or capital projects. Advanced electrical engineering, carbon accounting and financial modelling knowledge are not required.

A laptop is useful for reviewing course templates and working with sample data. Participants are encouraged to bring non-confidential utility, production or project information from a facility they know.

It suits energy, facilities, manufacturing, maintenance, sustainability and capital-project professionals working around industrial sites. It is particularly useful for people expected to turn energy targets into funded, operationally workable projects.

This course starts with manufacturing energy use, process constraints, utility systems and investment decisions. Renewable generation and procurement are addressed alongside efficiency, heat, electrification, metering and verified savings.

Participants can use the templates to establish a baseline, identify significant energy uses and develop a project pipeline. The project pack provides a structured basis for site reviews, capital requests and supplier discussions.

Training runs from 08:30 to 16:30 each day, providing about 6.5 contact hours daily. The first week builds data, auditing and utility-system methods; the second week covers transition options, finance, verification, governance and the capstone presentation.

Questions about this course?

Ask about dates, fees, group bookings or running it for your team. Our training team replies by email.

Ask on WhatsApp info@skillsetdevelopment.com

More courses in Energy Transition & Renewables

Energy Transition & Renewables Biogas Energy Systems Training Course 10 days · from USD 2,200 · next 16 Nov Energy Transition & Renewables Biogas Plant Construction and Maintenance Training Course 10 days · from USD 2,200 · next 16 Nov Energy Transition & Renewables Clean Energy Risk Analysis Training Course 5 days · from USD 1,100 · next 16 Nov Energy Transition & Renewables Renewable Energy Trends and Strategy Training Course 10 days · from USD 2,200 · next 16 Nov Energy Transition & Renewables Solar Energy and Energy Transition Training Course 10 days · from USD 2,200 · next 16 Nov Energy Transition & Renewables Strategic Leadership in the Energy Sector Training Course 5 days · from USD 1,100 · next 16 Nov Energy Transition & Renewables Sustainability Leadership in Energy Training Course 5 days · from USD 1,100 · next 16 Nov Energy Transition & Renewables Sustainable Urban Infrastructure Training Course 10 days · from USD 2,200 · next 16 Nov