Factory Energy Monitoring with AI Savings Recommendations
An energy monitoring system for factory lines that starts with the meters and SCADA you have. Recommendations name the load and the hours. Savings percentages are measured after a change, not promised up front.
Share recent bills and a meter list. We tell you what those data can already show.
Factory energy
kWh by line and shift
Maximum demand
Peak window on this curve
Power factor
From the plant meters
Solar
Grid
Energy per Machine, Line and Shift
An energy monitoring system for industry is a plant total until it is split. We line existing meters and SCADA up with machines, lines and shifts, and we put production beside the kWh so a quiet hour is not treated as a saving. Part of our Energy and Utilities work.
By machine
The meter or the feeder that serves one asset, so a compressor is not hidden inside the plant total.
By line
A line total when several machines share a feeder. Useful when the production plan, not a single motor, is the decision.
By shift
The same line on A, B and C shift. Idle hours and a tariff window show up only when the day is split.
Beside production
kWh next to the batches or metres the line actually ran, so a quiet hour is not praised as efficiency.
AI Savings Recommendations
The model ranks actions the meters support. Compressor energy saving is a frequent item, because unload hours and leaks sit in the data before a capital request does. Nothing on the list is a guaranteed percentage.
A named load
The recommendation names the asset and the hours. A plant-wide percentage is not a recommendation.
Compressor energy saving
Unload hours, short cycling and leaks are checked before anyone talks about a new compressor.
Schedule changes
A batch that can move out of the peak window is listed separately from a load that cannot move.
Ranked for the engineer
Items are ordered by what the meters support, and each one says what to measure after the change.
Maximum Demand and Power Factor Optimisation
An energy management system for factory bills has to read the demand charge and the power factor, not only the units. Both are already on the bill. The work is to see which hours and which loads create them.
Maximum demand
The peak the utility uses for the demand charge. The chart marks the window. It does not invent a new contract demand.
What can move
Compressors, pumps and batch equipment are reviewed for hours that sit on the peak. Continuous processes are marked as fixed.
Power factor
Lagging load shows up on the meters you already have. The trend is by shift, not a single monthly average.
Power factor correction panel
A panel is one possible action when the data supports it. We do not sell the panel. We show whether the plant should look at one.
Solar and Grid Mix
Rooftop and open-access solar change the unit rate. They do not automatically change the peak. The monitoring puts solar and grid on one day so the plant can see which loads follow the sun.
Hour by hour
Solar generation and grid import on one timeline, so midday export is not confused with the evening peak.
Which loads solar covers
Where feeders allow it, the mix is shown for the lines that can follow the sun and the lines that cannot.
Import still on the bill
Open-access or rooftop solar reduces units. Maximum demand can stay high if the peak hour is unchanged.
Meters first
Inverter portals and the utility meter are the start. A missing feeder meter is a sensor-partner question, not a guess.
Industries
The same method, different loads. Most of this work is with factories in Gujarat and elsewhere in India: textiles, ceramics, chemicals, pharma and engineering.
Textiles
Humidification, stenters, compressors and lighting across long sheds and several shifts.
Ceramics
Kilns and mills, where a continuous heat load and a batch load should not be averaged together.
Chemicals
Pumps, reactors and cooling, with a clear line between a safety-critical load and a deferrable one.
Pharma
HVAC and clean utilities, where a saving idea has to respect validated conditions.
Engineering
Machine shops, furnaces and compressors shared across job work and shifts.
Subsidy Support
A Gujarat MSME may be able to claim state assistance for an energy audit and for certain equipment. That claim has its own rules, its own documents, and a District Industries Centre check. This monitoring page does not decide eligibility.
Where the plant also wants failure watches on compressors and motors, that is a separate pilot. The audit path and the maintenance path can share the same meters.
What the assessment returns
- Which feeders the current meters already cover
- The demand window and the power factor trend
- A short list of actions to check
- Where a sensor partner would actually add a point
How It Works
The free energy savings assessment is the first pass. Ongoing monitoring is a later decision, after the baseline is visible.
Assessment
Bills, a meter list and a walk through the lines. We say what the existing data can already answer.
Connect
Utility meters, SCADA and feeder data. Sensor partners only where a load has no usable measurement.
Baseline
kWh by line and shift, the demand window, and power factor, before any recommendation is written.
Recommendations
A short list the plant engineer can accept or reject, each with a way to check it afterwards.
Monitor
Optional ongoing view so the next month shows whether the change held.
Results
Published figures wait until a client approves them. The assessment is how a plant sees its own list.
[client result: kWh moved out of the demand window]
[client result: compressor idle hours reduced]
[client result: power factor after the agreed action]
[client result: solar share of daytime load]
Results will be published as case studies with client approval.
Frequently asked questions
Common questions about factory meters, savings figures, solar, and Gujarat subsidy support.
What is an energy monitoring system for a factory?
It is the measurement and the view that split the bill into machines, lines and shifts, then recommend actions the meters can check. An energy management system for factory teams adds the routine: who reviews the list, and what gets tried next month.
Do we need new meters?
We start with the utility meter, SCADA and any feeder or machine meters you have. Where a load has no usable measurement, we bring in a sensor or meter partner. New hardware is the exception we name, not the default.
Will you quote a savings percentage?
No. The free energy savings assessment ranks actions on your data. A percentage published before that assessment would be a guess. After a change, we measure the same feeders again.
Can this see rooftop or open-access solar?
Yes, when the inverter portal or the solar meter can be read beside the grid import. The point is the mix by hour, including whether the peak still lands on the grid.
Is there subsidy support in Gujarat?
Gujarat MSMEs may be able to claim state assistance for an energy audit and for certain equipment. Eligibility is not decided here. See energy audit and Gujarat subsidy.
Get a Free Energy Savings Assessment
Bring recent bills and a meter list. We will show what the existing data can say about lines, demand and power factor.