Smart Energy Saving and Monitoring
An Industrial Efficiency Initiative
How we empowered a manufacturing plant to reduce operational costs and improve equipment efficiency through real-time energy tracking and predictive analytics.
High Energy Costs & No Visibility
A mid-sized manufacturing plant producing consumer goods aimed to reduce operational costs and improve overall equipment efficiency. The client faced challenges in tracking real-time energy consumption across machines, production lines, and plant zones, leading to high electricity bills and unoptimized resource utilization.
Key Pain Points
No Visibility: Lack of real-time power consumption data.
Energy Wastage: Idle equipment consumed power unnecessarily.
Inefficient Correlation: Difficulty linking energy use to production output.
Reactive Maintenance: No system to predict machine failures.
A Multi-Faceted Energy Optimization System
Hardware & Sensors
Deployed IoT energy meters and vibration sensors on critical machines to track voltage, current, and mechanical health in real-time.
Edge & Cloud Platform
Utilized edge gateways for local data processing and a centralized cloud dashboard for plant-wide analytics and AI-driven recommendations.
Productivity Analytics
Correlated energy consumed per unit produced to identify inefficient lines and calculate energy cost per product.
Intelligent Load Management
Optimized lighting and air conditioning based on occupancy and schedules to reduce power usage during idle times.
Predictive Maintenance
Used vibration sensors to detect early signs of bearing wear or imbalance in critical motors, preventing unexpected failures.
Behavioral Insights
Identified machines powered on too early or left running post-shift, alerting supervisors to prevent power drain.
From Cost Center to Efficiency Leader
40%
Energy savings from optimized lighting, AC, and scheduling.
15%
Cost reduction from predictive maintenance and fault detection.
Enhanced
Productivity by optimizing energy use per production unit.
By implementing Dream Filler’s Smart Energy Monitoring Solution, the client transformed its facility into a data-driven, energy-efficient, and sustainable operation, achieving measurable cost reductions and improved productivity.