Energy is killing Nigerian manufacturing margins.
For most Nigerian manufacturers, energy is the single largest operating cost — often 30 to 60 percent of total expenses. Diesel runs the plant when the grid fails. Steam systems leak. Compressors run inefficiently. Furnaces lose heat. Lighting wastes power.
And it adds up. A mid-sized factory burning ₦150 million a month on diesel and grid power could easily be saving ₦30 to ₦50 million of that — without changing what they produce or how much they produce. The waste is just baked into operations no one has audited.
Douxma exists to find that waste. We don't sell equipment. We don't push solar packages. We do energy engineering — measurement, analysis, recommendation, implementation, verification. The boring fundamentals that actually save money.
Energy engineering,
end to end.
Energy Audit
ASHRAE Level I, II, and III audits. Complete plant walkdown, instrumentation, baseline modeling, and detailed savings opportunity report with prioritized recommendations.
Efficiency Consulting
Strategic management. ISO 50001 implementation, energy management systems, KPI design, and continuous improvement roadmaps for ongoing efficiency gains.
Implementation Support
Project management for executing identified measures. Equipment specifications, vendor selection support, and commissioning oversight. Vendor-neutral throughout.
Measurement & Verification
IPMVP-compliant verification of post-implementation savings. Continuous monitoring through smart metering. Annual savings reports for management teams.
Engineering happens on the plant floor.
Every audit starts with our engineers on the ground — measuring, inspecting, and documenting real plant conditions across cement, food, steel, textiles, and chemicals operations.
TRUSTED BY MANUFACTURERS ACROSS NIGERIA
Engineering.
Not guesswork.
Walkdown
Our engineers walk your plant for 2-5 days. We see every system, every shift, every operation.
Instrument
We install power loggers and ultrasonic flow meters to measure actual consumption versus nameplate ratings.
Model
We build an energy baseline model of your plant — what each system should consume against actual use.
Recommend
A prioritized action list. Savings calculations, capital cost, and payback period ranked by ROI.
Verify
We verify actual savings against predictions using IPMVP methods. Real numbers, reported quarterly.
Built for Nigerian manufacturing.
Cement Plants
High-temperature kilns, raw mills, grinding circuits. Highest single-plant users.
Food & Beverage
Refrigeration, steam, compressed air. Significant losses in steam systems are typical.
Steel & Metals
Furnaces, rolling mills, induction. Heat recovery is a major opportunity area.
Textiles & Garments
Boiler systems, dyeing, drying. Steam distribution losses are common.
Chemicals
Reactor systems, distillation, utilities. Process heat integration delivers savings.
FMCG
Mixed processes, packaging, compressed air and motor systems are key.
We bring the meters.
No guesswork.
Our engineers carry calibrated instrumentation to measure real plant performance. Power, flow, temperature, pressure, ultrasonic — captured shift by shift.
Hioki PW3360
Three-phase power loggers. Captures real load profiles across shifts and startups.
Sierra InnovaSonic
Clamp-on ultrasonic flow meters for water, steam condensate, and process fluids.
FLIR T-Series
Thermal imaging to find heat losses, insulation gaps, electrical hotspots, and steam leaks.
Testo 350
Flue-gas analysers for boilers, kilns, and furnaces. Combustion efficiency and excess-air tuning.
Audited. Implemented. Verified.
"Identified ₦340M annual savings through grinding circuit optimization."
Optimization through classifier replacement and ball charge adjustment delivered measurable savings within 3 months.
"Reduced steam consumption by 28% through leak elimination."
Detailed steam system audit identified 47 separate leaks and inefficient traps. Remediation reduced fuel consumption substantially.
"Cut compressed air costs by 38% with no equipment investment."
Audit revealed major losses and pressure setpoint issues. Operational changes delivered savings without new equipment.
Engineered to international standards.
Energy efficiency is a real engineering discipline with established international standards. Our team holds relevant certifications and operates to methodologies recognized globally.
Energy Management Systems Auditor
Energy Audit Standards
Measurement & Verification Protocol
Certified Energy Manager (AEE)
Certified M&V Professional
Council for Engineering in Nigeria
Nigerian Society of Engineers
Energy Commission of Nigeria
Find out what your
plant is wasting.
A scoping call takes 30 minutes. A preliminary energy review takes 2 weeks. A full ASHRAE Level III audit takes 4-8 weeks. Every engagement starts with a conversation.
Energy services for high-stakes
manufacturing decisions.
Five service areas. Built for the questions Nigerian manufacturers actually face. Engaged on a project, retainer, or embedded basis.
Energy Audits
Where the savings actually are.
An energy audit is the foundation of any efficiency program. Before recommending any investment, our engineers measure what your plant actually consumes — system by system, shift by shift, against engineering benchmarks for what it should consume.
Quick assessment of obvious savings. 3-5 day engagement. Best for initial scoping.
Comprehensive plant analysis with on-site measurement. 4-8 week engagement.
Full instrumentation and baseline modeling for major capital decisions. 8-12 week engagement.
Efficiency Consulting
Beyond a single audit.
Energy efficiency isn't a one-time project — it's an operating discipline. Our efficiency consulting engagements help you build internal capability, governance, and systems for sustained improvement.
- ISO 50001 implementation support
- Energy KPI framework design
- Operator training programs
- Energy team mentoring
Three ways to work with us.
One-off engagement
Defined scope, timeline, and deliverables. Best for audits and specific technical questions. Typical 4-12 weeks.
Ongoing partnership
Continuous energy advisory across multiple sites. Best for groups with sustained efficiency programs.
Resident engineer
A senior energy engineer placed on-site for 6-12 months. Best for major capability building.
How we do energy
engineering, in detail.
Energy efficiency consulting can be vague. We aim to be the opposite. Here's exactly how we work and what you can expect.
Initial walkdown, Lagos brewery, 2025
Walking the plant.
Every engagement starts with our engineers physically walking your facility for 2-5 days. We see every operating shift, every system, every process. No remote analysis substitutes for it.
- Plant energy profile inventory
- Initial savings hypothesis
- Recommended audit scope
Measuring what matters.
We install temporary instrumentation — power loggers, ultrasonic flow meters, thermal imaging — to measure real performance against nameplate ratings. We capture operability variability, startup, and shutdown loads.
- Hioki & Fluke power loggers
- Sierra ultrasonic flow meters
- FLIR thermal imaging
Build the should-cost.
From measured data we build an engineering baseline of what each system should consume given output and conditions. The gap between measured and modelled is the addressable savings.
- System-by-system specific energy
- Output-normalised consumption
- Best-in-class benchmarks
Ranked by ROI.
Every opportunity is sized in naira, costed for capex, and ranked by payback. Operations gets a roadmap they can execute. Finance gets a business case they can sign off on.
- No-cost / low-cost actions first
- Capex projects with payback < 24 mo
- Strategic capital projects
Prove the savings.
Post-implementation, we verify actual against predicted savings using IPMVP methodology. Permanent metering tracks performance ongoing — quarterly verification reports give management confidence the gains are real and durable.
- IPMVP Option B/C protocols
- Permanent sub-metering
- Quarterly verified reporting
What every Douxma engagement delivers.
Audit Report
Technical report documenting energy use, modeling, and ROI-ranked recommendations.
Executive Brief
Management-ready summary of findings and proposed implementation roadmap.
Roadmap
Practical sequencing plan for executing recommendations with timeline and capital reqs.
M&V Reports
Quarterly verification reports tracking actual versus predicted savings.
Where industry knowledge
meets energy engineering.
Industry expertise isn't optional in energy auditing. The opportunities in a cement plant are completely different from those in a brewery or a steel mill. Our engineers have spent years embedded in the industries they serve.
Cement
KILNS, RAW MILLS, GRINDING CIRCUITS
Cement is the most energy-intensive sector in Nigerian manufacturing. A typical 1 MTPA plant consumes 1.5–2.5 GWh per day. Energy is 30–40% of total cost.
- KILN COMBUSTION AIR
- COOLER HEAT RECOVERY
- GRINDING CIRCUIT UPGRADES
- VFD DRIVE SYSTEMS
Food & Beverage
REFRIGERATION, STEAM, PROCESSING HEAT
Steam systems are almost always the largest opportunity — leaks, trap failures, and inefficient distribution are universal issues in Nigerian food plants. Refrigeration runs second.
- STEAM LEAK ELIMINATION
- BOILER OPTIMIZATION
- REFRIGERATION CYCLES
- HEAT RECOVERY
Steel & Metals
FURNACES, ROLLING MILLS, INDUCTION
Heat recovery is the single largest untapped opportunity in Nigerian steel. Reheat furnaces, EAF off-gas, and rolling mill drives consume disproportionate energy with major optimization potential.
- FURNACE OPTIMIZATION
- OFF-GAS HEAT RECOVERY
- INDUCTION TUNING
- DRIVE EFFICIENCY
Textiles & Garments
BOILERS, DYEING, DRYING
Steam distribution losses dominate textile plants. Dye-house heat, drying ovens, and compressed air round out the major opportunity areas.
- STEAM DISTRIBUTION
- DYE BATH HEAT
- DRYER OPTIMIZATION
- COMPRESSED AIR
Chemicals
REACTORS, DISTILLATION, UTILITIES
Process heat integration is where chemicals deliver the largest savings. Pinch analysis routinely identifies 15–25% reductions in steam and cooling-water demand.
- PINCH ANALYSIS
- DISTILLATION TUNING
- COOLING TOWER OPS
- UTILITIES BALANCE
FMCG
PACKAGING, MIXED PROCESSES, AIR
Compressed air and motor systems dominate FMCG operations. Lighting, HVAC, and packaging line motor sizing all add up across high-throughput plants.
- COMPRESSED AIR SYSTEMS
- MOTOR RIGHT-SIZING
- LIGHTING UPGRADES
- HVAC TUNING
We work where energy
is a hard cost line.
Pulp & paper, ceramics, plastics, pharma — the engineering principles transfer. If energy is more than 15% of your cost base, we should talk.
Talk to an engineerAudited. Implemented.
Delivered in naira.
Identified ₦340M annual savings in grinding circuit optimization.
Detailed measurement of two parallel grinding circuits identified excessive specific power consumption. Optimization delivered measurable savings within 12 weeks of audit completion.
DURATION: 12 WEEKS AUDIT + 6 MONTHS IMPLEMENTATION
Reduced steam consumption by 28% through leak elimination.
Ultrasonic leak detection identified 47 separate steam leaks across the plant. Thermography revealed extensive underinsulated pipework. Remediation reduced fuel consumption substantially.
DURATION: 8 WEEKS AUDIT + 4 MONTHS IMPLEMENTATION
Cut compressed air costs by 38% with no equipment investment.
Audit revealed major leakage and a 2.4-bar pressure setpoint that exceeded actual process needs. Operational changes — leak campaigns, pressure reduction, and sequencing logic — delivered savings without any new capital.
DURATION: 6 WEEKS AUDIT + 8 WEEKS IMPLEMENTATION
Recovered 2.8 MW of waste heat from reheat furnace flue gas.
Stack thermography and combustion analysis identified ~280°C flue gas with no recovery. We specified a recuperator retrofit that pre-heats combustion air, cutting fuel demand without disrupting production scheduling.
DURATION: 10 WEEKS AUDIT + 7 MONTHS IMPLEMENTATION
Cut diesel-generation costs by 22% across 6 plants.
A multi-site retainer engagement profiled diesel generator dispatch, loading, and standby behaviour. Right-sizing, parallel-operation logic, and load-shedding rules eliminated low-load running and oversize-genset waste.
DURATION: 12 MONTHS RETAINER,6 SITES
Douxma found ₦340M of savings in the first 12 weeks. Their team measured what we had stopped questioning.
— OPERATIONS DIRECTOR, TIER-1 CEMENT MANUFACTURER
We exist to engineer
Nigerian manufacturing efficiency.
Douxma was founded in 2018 by senior energy engineers from major international consultancies and Nigerian industrial operators.
We started Douxma because Nigerian manufacturing was bleeding money on energy with almost no specialist firms available to help. We chose to focus only on energy — not as one service among many, but as our entire practice.
Today we work with cement majors, food & beverage groups, steel mills, and chemicals manufacturers across Nigeria. Most of our work comes from referrals — Nigerian manufacturing is small enough that good results travel quickly.
Three commitments. Non-negotiable.
Vendor neutral
We don't sell equipment, take commissions, or carry exclusive supplier relationships. Our recommendations serve your plant, not a vendor's pipeline.
Measured, not modelled
Every claim we make is backed by on-site measurement. We do not deliver desk audits or template recommendations dressed up as engineering.
Verified in naira
Savings only count when verified. IPMVP-compliant M&V on every engagement. The number on the audit report is the number we'll defend in 12 months.
Engineers, on the floor.
Tell us about your plant,
and what you want to audit.
Most engagements start with a 30-minute scoping call. No prep needed — just bring an honest sense of where your energy bill hurts.
For media and analysis enquiries:
admin@douxma.org
Garki II, Abuja
2 Moshood Abiola Way
Abuja 900001, Nigeria
Start a conversation.
Tell us about your plant — what you make, your monthly energy spend, what's hurting most. We'll recommend an approach and let you know if we're the right partner.
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Effective Date: April 24, 2026
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Terms of Service
Effective Date: April 24, 2026
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Professional Standards
Douxma follows international standards (ASHRAE, IPMVP, ISO 50001). We are vendor-neutral and do not accept commissions from equipment suppliers.
Liability
Our liability is limited to fees paid for the specific engagement except in cases of gross negligence. Audit recommendations are professional opinions based on engineering analysis.