We operate three shifts and have noticed repeated demand spikes during changeovers — especially between first and second shift when equipment overlap is highest.
We don’t currently have any kind of automated demand control, just basic interval data from our utility.
Has anyone successfully reduced peak demand during shift transitions in a heavy industrial setting?
I’m looking for ideas that don’t require a full controls upgrade but still deliver results.
Hey Lucas, that first-to-second shift overlap is one of the most common times we see demand spikes, especially when crews are powering up machines early while the outgoing shift is still wrapping up.
One thing that’s helped other facilities in a similar setup is creating a quick-start procedure where heavy-load equipment gets brought online in stages. Doesn’t require controls just a bit of coordination or even low-tech timers on key equipment. I’ve also seen some sites manually delay non-critical loads by 10–15 minutes just to soften that overlap.
Since you’ve got interval data, you might be able to pull a few days’ worth of profiles and map the spike directly to specific load activity could help you target just the machines that matter most.
Is there a specific process area or type of equipment where you think most of the spike is coming from?
Thanks for the response. We do have interval data from our utility, but I haven’t looked closely at the overlap windows yet. I’ll try pulling a few days to see where the spikes are landing. Staggering start-up sounds doable. We don’t have timers set up, but I might be able to coordinate it manually for now and see if it makes a difference. I appreciate the help.