Experience and case studies

Demand regularly exceeds the contracted power. In this particular case, the contracted power is 1,000 kW and peaks above 1,500 kW have been recorded. Maximum demand meters are specific to each tariff period.

The contracted power was adjusted, some inefficient equipment was replaced and equipment use was rescheduled across time periods.

High consumption is detected during non-productive periods. For our client, the optimised residual consumption over a weekend is 40 kWh, yet 130 kWh is being recorded.

Certain equipment is now switched off automatically using our IoT solution, and an alert is sent to the person responsible for shutdown.

Several machines in the factory start up at the same time.

• Extra costs from excess power demand.
• Tripped protection devices.
• Transformer wear.
• Cable overheating.

A staggered start-up is scheduled and motors with electronic soft-start, star-delta and VFD starting are added.

The system sends an email and mobile alert when the power factor drops below the reference value.

The reactive energy penalty is avoided.

Scenario A.

• Compressor 1: Alternates load/unload cycles (start-stop).
• Compressor 2: Running loaded.
• Compressor 3: Running unloaded (the motor turns but does not compress).

Scenario B.

• Compressor 1: Running loaded.
• Compressor 2: Off.
• Compressor 3: Modulates, supplying only what is needed.

By detecting broken resistors and dropped phases, the system monitors whether machinery is working correctly. 

This prevents breakdown stoppages. Missing the alert would have a very high cost and/or quality impact.