Three Factors Determining Fuel Consumption in a Manufacturing Plant

10/06/2026

In industrial manufacturing, the decision on which fuel to use is often determined very early on, sometimes even before the factory begins construction. It's not simply a cost calculation, but rather a consideration of the entire factory process.

Below is a simple way to better understand the three levels influencing fuel selection in a manufacturing plant. This is an observational perspective from reality, not an absolute technical conclusion.

Level 1 — Production Process Requirements

Each production process sets different thermal requirements (SPEC): operating temperature, flame characteristics, combustion chamber environment (oxidizing or reducing), and cleanliness of combustion products. These requirements are determined during the design phase of the specific product manufacturing process.

A ceramic kiln operating at 1,200–1,400°C with strict combustion chamber environmental control requirements will have a very different list of suitable fuels compared to a boiler supplying heat to a food processing line at 150–200°C. Not every gas will meet all process requirements.

This is why the "most cost-effective" fuel is sometimes not a technically viable option.

Level 2 — Equipment and Burners

Equipment that directly impacts the production process, such as burners, boilers, and machinery in the production line, is selected according to the required SPEC (Specific Temperature and Pressure) at Level 1. Furthermore, these machines and equipment are often pre-configured by the manufacturer for a specific fuel before being sold to the market.

This means that when a production line imported from Japan or Germany is configured for LPG, switching to CNG or LNG is impossible or not straightforward. It may require equipment adjustments or replacements, system retesting, and temporary shutdowns.

Then, during operation and improvement, fuel switching options may be considered. However, we must return to step 1 to evaluate the most important "character"—the MACHINE or BURNER.

This is the most common problem DATA encounters when working with clients during the consulting process.

Level 3 — Combustion Characteristics of Each Gas Type

Industrial fuel gases—LPG, CNG, LNG—have different combustion characteristics, measured by a technical index called the Wobbe Index. The Wobbe Index is used to assess the interchangeability of fuel gases in the same combustion system.

See details of the Wobbe Index

LPG belongs to a separate fuel group, with a significantly higher Wobbe Index than CNG and LNG—which belong to the same group. This gap is large enough that direct swapping between LPG and CNG/LNG without technical adjustments is not feasible in most cases. Meanwhile, switching from CNG to LNG or vice versa is generally less complicated due to their similar combustion characteristics.

Of course, the specific level of complexity depends on the type of equipment and manufacturer—this is the part that requires direct assessment by a combustion equipment engineer, not the gas supplier.

In short, these three stages are not independent—they are connected in a certain direction:

The production process sets the heat requirement → Equipment is selected to meet that requirement → Equipment determines the appropriate gas type.

In practice, when a plant wants to change fuel, the question isn't "which one is cheaper?" but rather should start with "can the existing equipment support it, and when is the right time to intervene?"—usually during a routine overhaul, line expansion, or replacement of equipment.

This is our perspective when working with factories considering a transition. If you are in that stage, DATA Energy is ready to sit down and better understand your equipment status and find the right direction — even if the final answer might be "not the right time yet."