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case study

Reducing Electricity Bills

Industries are billed on different electricity tariffs, including peak and non-peak hour rates, where peak-hour tariffs are significantly higher. If a few machines consume excess current unnoticed, it can lead to substantial electricity cost increases. A smart monitoring solution with analytics and automated control can help industries optimize energy usage by limiting machinery operation during peak hours. Additionally, monitoring machine vibration and heat can detect anomalies in power consumption, indicating inefficiencies or potential failures. Implementing such a system enhances operational efficiency, prevents energy wastage, and reduces costs. Advanced analytics provide insights for predictive maintenance, ensuring machines run optimally while avoiding unnecessary electricity expenses during high-tariff periods.

Reducing Electricity Bills

The Pain

  • There is no visibility on machine-wise power consumption on the factory floor.
  • Operators run the machines in peak hour time which was rather instructed to be run during non-peak hour time, leading to high energy bills.
  • Downtimes are not reported properly, and frequent outages are a sign of near future malfunction.

The Solution

  • Power supply of each machine was provided through an IoT enabled panel or smart plug.
  • Panel meters were also connected to the IoT platform through our IoT gateways.
  • A web and mobile app was developed to receive the following alerts: Peak hour alerts
  • Machine-wise consumption alerts
  • Down time alerts

Benefits

  • Up to 13% reduction in energy bills.
  • Remote / automatic shutdown of power supply to the machine when operated in peak hour mode.
  • Instant reporting of downtime and hyper consumption beyond rating, calling for maintenance.
  • Insights into energy consumption pattern.