Sustainable industrial shop floors through Energy & Resource analytics

Globalization has made all the markets fiercely competitive and cost conscious. In addition, there is increasing awareness about environmental impact of industrial activities and customers are demanding environment friendly production. 

Industries, competing in the global markets, need to be mindful of both, production costs as well as environmental impact of their activities. Rising energy costs and increasing awareness of adverse environmental impact has made increasing energy efficiency and cutting energy losses, a necessity, to be able to survive in these competitive markets. 

The quantum of ‘Energy Savings’ and ‘Energy Efficiency’, can only be realized, if you know ‘how much’ of energy is being consumed and ‘where’ the losses are taking place in the production processes. An accurate and real-time monitoring is thus a necessity for reducing energy costs and increasing environmental friendliness. 

Industries usually rely on the monthly electricity bill to judge energy performance of their plant, but a monthly energy bill can only provide a broad picture, which isn’t enough to analyze the energy distribution and doesn’t provide actionable information.

For proper analysis real-time energy data is of utmost important.

In general, this data collection activity could be done manually but is tedious, time consuming and prone to errors. Also, since this manual activity is not real-time, many opportunities to take immediate action are lost. As a result of all these factors, energy efficiency/conservation activities get sidelined resulting in mounting energy losses contributing to excess production costs.

Most of energy losses are quantifiable, if a real-time measurement system is deployed and can be eliminated or reduced by taking appropriate action.

Some typical problems in an Industry are as follows:

• ●    Wastage: Industries face average energy wastage of 1-3% due to various reasons.

• ●    Failure to quantify or realize daily energy losses due to lack of energy monitoring.

• ●    Human errors in manual energy monitoring. 

• ●    Energy Efficiency NOT being a priority for the organization due to lack of data.

• ●    Unawareness about benefits of international standards such as:

- ISO50001: Energy Management System.

- IEEE standards in Power Quality, and

- Governments initiatives such as Industry 4.0

Inability of the Maintenance Team to demonstrate CarbonMinus.com is Internet of Things (IoT) based Energy Analytics and Monitoring system, which comes with a hardware controller and Software-as-a-Service (SaaS) online platform, that assists industries to gain competitive advantage by gaining energy efficiency and compliance.

First and foremost, CarbonMinus makes it easy to collect real-time data and presents it on a web portal that is accessible to the operators, owners of the plant, anywhere across the world.

CarbonMinus’s custom built controller collects the data in real-time through RS485 based energy meters, and transmits it to CarbonMinus’s cloud platform,  where it is analyzed and displayed on the online secured portal. The online secured portal can be accessed using right credentials (login/password) through any digital devise having Internet connectivity.

Different plant and application level parameters are displayed which are updated in real time. Under the hood, CarbonMinus also operates a complex algorithms that analyzes parameters against different national and international standards like ISO50001: Energy Management System (EnMs).

In addition to usual parameters like Energy Consumption kWh, Energy Cost in Rupees, Real Time Demand kVA that are in other solutions seen in the market, CarbonMinus also provides advanced analytical parameters like Specific Energy consumption (kWh per unit of production), Specific Energy Cost and Specific Emission (after production input) along with some international parameters in accordance with ISO50001.

Moreover, CarbonMinus provides real-time Alerts and Notifications on important parameters, if they are crossing the predefined threshold values thus helping the operators to take quick remedial action.

CarbonMinus provides detailed data and charts that can be used to compare plant and machine level consumption with industry level ‘Energy Benchmarks’ and providing actionable information to plant operators and owners.

CarbonMinus’s advanced system can also provide insightful information to the maintenance teams of undesirable trends by providing data about machines power performance using parameters like overloading current, unbalances or power quality etc. which is also known as conditioning monitoring and helps save major plant breakdowns by enabling preventive maintenance.

 In addition to all these features, CarbonMinus also provides daily reports on plant performance. SMS’s and Emails keep operators informed and in sync with their industries shop floor parameters.

Road map for energy efficiency and conservation can be built on feedback received from analytics software and before and after picture can be affirmatively presented using the SaaS platform.

‘CarbonMinus’ has government empaneled certified (Bureau of Energy Efficiency) Energy Auditors to help industries stay on the right path and to have pragmatic approach towards their energy efficiency practices.   

CarbonMinus is designed and developed by experienced technologists and energy auditors, continuously optimizing and updating the software platform. CarbonMinus is an important tool for MSMEs as well as large scale industries enabling them  to face global competition with Energy Efficient performance…!!!

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