Excessive Steam Consumption in Conditioning and Casing

$20,800-$25,000/month in wasted steam energy (based on 19-21% potential savings documented in tobacco manufacturing energy audits); extrapolates to $249,600-$300,000/year in pure energy waste from over-supply • Excess steam generation and dispersion in conditioning and casing drives 10–25% avoidable steam overuse in the primary workshop, which in a mid‑size factory translates into roughly $15,000–$40,000 per month in fuel, water, and treatment chemicals, plus incremental boiler maintenance and CO2 costs, directly impacting annual economic performance.

Manual boiler operator adjustment using past experience and intuition; spreadsheet logging of steam consumption; portable combustion analyzers used periodically (not continuous) • Steam supply is set and adjusted by rule-of-thumb and past experience, with operators informally coordinating via phone/WhatsApp and recording boiler/line readings and setpoints in paper logs and Excel sheets at the end of the shift instead of using a predictive dispatch system.