Challenge:

• Recurring power surges causing unplanned downtime to critical production equipment.
• No real-time monitoring capability, subjective assessment, maintenance intervention reactive.

eC4 Solution:

24x7 tracking of power quality characteristics (voltage & current unbalance, Power Factor, harmonics).

Results:

• Critical on-site visibility & intelligence into power quality incidents.
• Understanding the magnitude & frequence of occurrences - proactive maintenance.
• Live tracking of Power Factor to reduce utility penalties.

Challenge:

• No Intelligence into Boiler Performance.
• Inability to Translate Raw Sensor Data into Performance Issues.

eC4 Solution:

• Real-Time Intelligence into Boiler KPIs, Process Variables & Energy Use.
• Rules-Based & Unified Anomalies Intelligence with KPIs correlation.

Results:

• Proactive Identification of Low Excess Air levels;
• Uncovering of High Operational Pressure;
• 24x7 Understanding of Boiler Efficiency.

Challenge:

• Manual monitoring of energy use – time-consuming, inaccurate, and resource-intensive.
• High utility penalties due to addition of new equipment and production activity expansion.
• Inability to extract energy data from equipment – either meters or legacy assets.

eC4 Solution:

• The Edge Device integrated with all plant energy meters for 24x7 kW, kWh and energy intensity tracking and smart analytics at the individual machine level.

Results:

• 12-15% reduction in energy costs in 6 months.
• Elimination of utility penalties from 2 per month to 0.
• ROI < 1 year.

Challenge:

• Inability of the c-suite to benchmark their presses’ daily business activities with equipment operating cycles.
• Inability of c-suite to understand the usage, peak loading, and the frequency of electrical demand across their printing plants.
• Lack of real-time visibility into daily energy use at the plants.

eC4 Solution:

• 24x7 remote energy use monitoring of printing presses & Air Handling Units (AHUs) from HQ.
• Dynamic baselining 7 benchmarking of energy use, along with correlating run hours of presses vs. AHUs.

Results:

• Critical identification of energy waste - off-hours & excess AHU operations.
• Implementing of energy-saving strategies e.g. load-shedding.
• ~10% reduction in annual energy costs per plant.

Challenge:

• Varying temperature and humidity at labs impacted electronic parts produced.
• Need for a central visualization and control center for geographically distributed labs.
• Trigger predictive alarms due to undesirable temperature & humidity gradients

eC4 Solution:

• Real-time tracking of ambient humidity & temperature profiles across all labs using related sensors.
• Integration with resident Building Management System to control HVAC system.

Results:

• Remote visibility into lab temperature & humidity profiles, with proactive alerts of anomalies.
• Decrease in damaged parts & increased lab availability.
• Reduce monthly energy costs.

Challenge:

• Paint shop high contributor to annual energy costs – no visibility into energy use.
• No granular insights into operating performance of paint shop assets.

eC4 Solution:

• Connected to various electrical meters and temperature controllers of two different plants’ paint shops.
• Unified energy intelligence dashboard.
• 24x7 tracking of key paint shop assets e.g. compressors, transformers, chillers.

Results:

• Dynamic daily understanding of paint shops’ contribution to the energy bill at both plants.
• Ability to correlate energy use with production activity, and track kWh/tractor.
• Proactive identification of energy waste and anomalous performance of process variables.