We develop and implement energy management systems for production plants. allowing for the implementation of energy cost savings and ongoing monitoring of production efficiency. We supply measuring sensors for current, fluid flow and temperature measure
We develop and implement energy management systems for production plants. allowing for the implementation of energy cost savings and ongoing monitoring of production efficiency.
We supply measuring sensors for current, fluid flow and temperature measurement. We install energy meters on selected equipment/lines/plants, so that we can accurately monitor energy consumption at any time, on any component. The customer receives very precise data on energy consumption, instead of an overall value read from the meter.
Electricity monitor with online measurement.
- Measurements are taken every 5 seconds and sent to an online database.
- Installation of the sensors is quick and non-invasive.
- No need to switch off the machine (installation is done on a DIN rail).
- The maximum current loads are 100 A, 200 A and 400 A.
- It is also possible to individualise the maximum load values.
Ultrasonic flow sensor with online measurement.
- Fluid temperature measurements are taken every 5 seconds and sent to an online database.
- Installation of the sensors is non-invasive, does not require drilling into the system pipes and is possible anywhere in the pipeline.
- Measurement diameters range from 50 mm to 700 mm.
Cloud-based EMS system.
- We also provide a dedicated system for these sensors, allowing data to be monitored from any location.
- It also allows multi-user logging from both PCs and mobile devices.
How does the process look?
We install flow and energy sensors at key points (on equipment, lines, in selected areas of the factory).
We then collect the data and convert it into heat or cost values.
Once we start working together, we arrive and define the critical points of the plant that can generate potential savings.
We install the devices non-invasively at pre-selected points. This does not require production to stop and therefore does not generate additional costs.
The data collected can be analysed either directly by you or by us, and we will make the results available to you in the form of a report after the audit.
It is possible to organise a follow-up meeting to discuss the results of the monitoring, suggest improvements and define a plan for further action.
Depending on the customer's expectations, we continue to measure at the indicated points or increase the number of sensors. This is in order to achieve even more precise measurements and thus greater savings.
At the customer's request, we customize the system to meet specific needs or integrate it with an existing database.
Customer benefits - monitoring results and production optimization
Knowing the current state of energy consumption at any point in production, as well as being able to check its use in the past for comparison purposes.
To know the actual cost of producing one unit of a given product, taking into account the parameters at which it is made.
Receive specific alerts when a specific energy consumption is about to be reached, with the aim of eliminating overruns of the plant's connection power and the resulting penalties.
Knowing the actual unit costs of production, taking into account the parameters at which it takes place.
We become familiar with the line's operating cycles, where we can determine the cost of each phase of the operation, e.g. product change, ingredient change, washing/start-up.
Our monitoring enables the client to verify the profitability of a plant upgrade by comparing the results before and after servicing, for example.
We prepare recommendations for production planning, in which we take into account the profitability of production and help to plan the modernisation.
- After obtaining the data, we perform a data analysis, looking for points with potential for optimising consumption.
- We check the points where it is possible to reduce consumption by adjusting the overall plant.
- We prepare a report setting out the potential savings and costs of implementing the changes.
- The client decides whether we develop the collaboration, increase the accuracy of the plant's measurements, and move on to other areas of the factory.
- If so - we move on, analysing further production processes and breaking down the entire sector into individual components.
- Sensors can be hired on a subscription basis for the duration of the work.
- Installing the sensors does not require production to stop.
Examples of applications
1. Profitability analysis of production
- The client has a procedure for running the process. He knows the average cost of production, but not how much each component costs him. From time to time, the largest customer comes in with a request to produce a small batch of a product, which requires a batch change, the preparation of a new batch and the start-up of the plant .
- Thanks to monitoring, we know the energy intensity of each stage. We are able to determine the cost of producing each batch of product, depending on the cycle time.
- We can determine precisely how much it costs to carry out unexpected orders that require production stops and starts.
2. Control of production guidelines
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The plant has a cold store that maintains a temperature of -20◦C and production takes place from Monday to Friday from 8am to 8pm.
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The client approached us to find out how much it costs to open and close the cold store doors, and how much it costs to keep the doors open throughout production.
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After analysis by our company, the client found out that by using automatic door closing or the introduction of sleeves, he could save up to £4,000 a month.
3. Heat loss calculation
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There is a chiller plant, at the extreme point of the plant, where glycol is transported at a temperature of -15 ◦C. This is transported by pipelines to all areas of the plant.
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The client approached us to find out how much glycol is transported to the various locations in the plant, and thus what the distribution of heat lost in the various sectors is.
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Analysis of measurements and heat transfer calculations determined the optimum insulation thicknesses in the individual sectors, which translated into approximately 30% lower insulation costs.
4. Detection of idle operation of equipment
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The client owns a plant involved in steel production. He made a request to identify what consumes a large amount of energy in the company.
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Through monitoring, it was possible to determine that an 80 kW fan, used to ventilate the hall during production, was also switched on during weekends when the plant was not working.
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The fan was switched off and costs were reduced by more than £6,000 per month.
5. Investment viability analysis
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The customer is planning to upgrade the ball mills and is considering the purchase of new equipment. There is a big price difference between the two chosen models, but at the same time the more expensive model has a higher efficiency.
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The customer approached us to compare the models. Both machines were put into production and Quickersim sensors were connected.
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Analysis showed which of the models considered would be more cost-effective for the line to be designed, and costs were reduced by 15%.
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Call: 789 477 246.