Assessment of Energy Performance in Liquid Carton Packaging Manufacturing

Energy efficiency has become vital for improving sustainability and operational effectiveness in manufacturing. In liquid carton packaging processes like printing, extrusion and lamination are highly energy intensive. Therefore it is important to evaluate energy performance to identify inefficiencies to guide system optimization. This paper presents an in-depth performance analysis of energy use and optimization in a liquid carton manufacturing facility in Kenya. The study applied process level audits, digital energy monitoring, and key performance indicators such as load factor, energy intensity, and power factor to assess energy use. Observations reveal that compressed air systems, chilled water plants, and idle machine loads contribute significantly to energy waste. Digital monitoring tools like Schneider EcoStruxure and Sunny Portal support real time diagnostics and performance tracking. The study recommends integrating energy audits into maintenance planning, using simulation tools for demand forecasting, and aligning energy insights with production control. These findings offer practical strategies to improve reliability, reduce downtime, and enhance resource planning in energy intensive manufacturing environments.