Energy efficiency and savings in automotive industry, case study: Tenneco, Inc

The present work focuses on energy efficiency and savings achieved at Tenneco’s Chivasso plant (Turin), one of the leading production sites in the powertrain sector of the automotive industry. During my internship, I managed and implemented several initiatives aimed at reducing energy consumption, lowering operational costs, and minimizing environmental impact. The activities carried out involved multiple areas of intervention, among which the optimization of compressed air systems, the revamping of internal lighting, the introduction of new energy KPIs, and the implementation of a shutdown program for production lines. Moreover, a preliminary analysis of photovoltaic systems for on-site renewable energy production was performed. Compressed air system optimization was conducted by gradually lowering the operating pressure from 7.1 bar to 6.6 bar, resulting in an annual saving of approximately 17 k euros, corresponding to about 83 MWh/year of electricity saved and 34 tons of CO₂ avoided. The payback time for this no-cost intervention was immediate, with savings achieved after the first month of operation. The lighting system revamping project involved replacing 1,060 fluorescent tubes (18W each) in office areas with new LED technology (6.6W per unit). The intervention led to an energy saving of about 33 MWh/year, a cost saving of around 7 keuros/year, and a CO₂ emission reduction of 14 tons/year. The payback time of this investment was estimated at 10 months, making it highly convenient for immediate implementation. Energy monitoring and KPI introduction activities allowed to identify the specific energy consumption (€/unit produced) for each major machinery in the plant. The shutdown guide for production equipment was developed with the maintenance and production teams. By correctly shutting down machines during weekends and downtimes, and in addition a better awareness among operators and maintenance teams, improving operational behavior further energy savings of approximately 25 MWh/year and 5k euros/year were achieved, with a CO₂ reduction of about 10 tons/year. The preliminary photovoltaic plant feasibility study suggested the possibility to install a system of around 373.80 kWp on the factory roof. The estimated production would be about 533 MWh/year, covering 15% of the site's annual consumption and reducing CO₂ emissions by approximately 331 tons/year. The payback time was estimated at 6-7 years without incentives, and 3-4 years with possible state subsidies. Totally the interventions carried out or designed during this work allow for the following cumulative savings: •??Electricity saved: approximately 809 MWh/year •??Economic savings: approximately 162k euros/year •??CO₂ emissions avoided: approximately 331 tons/year These results demonstrate that even low-investment or behavior-driven actions can have a significant impact on both the economic and environmental performance of an industrial site. The methodology adopted can serve as a reference model not only for the Chivasso plant but potentially for other Tenneco sites worldwide, especially in a context where energy transition, sustainability, and energy security have become increasingly strategic issues for the automotive sector. Through this work, it is confirmed that improving energy efficiency is a fundamental step towards achieving corporate sustainability goals, maintaining competitiveness, and contributing to a greener and more responsible industrial future.