Manufacturing: Automotive, Plastics & Rubber

Tier 1 and Tier 2 manufacturers often have detailed production data but limited visibility into the utilities supporting it. Compressed air may be unmetered, demand charges may sit inside overhead, and critical legacy presses may not have a modern PLC. We add read-only monitoring, connect existing data sources and leave the control layer unchanged. The same measured data can support ISO 50001 energy-management programs and customer reporting.

Compressed air is often the first place to look for avoidable cost. It is expensive to generate, frequently lacks end-use metering and can leak unnoticed in a noisy production environment. A planned shutdown test using permanent flow monitoring can quantify leakage by cell, rank repair priorities and establish a baseline for verification.

Electrical demand is another common opportunity. Depending on the utility tariff, a short interval can establish a significant portion of the monthly demand charge—for example, when a dryer regeneration cycle and compressor load coincide. Interval monitoring identifies the peak, the contributing equipment and whether rescheduling can reduce it without new capital equipment.

Critical equipment often shows measurable changes before failure, including shifts in vibration, temperature or motor current. Legacy assets are well suited to independent monitoring: mount a vibration sensor on the housing, clamp a current transformer on the motor feed or read an existing 4–20 mA signal. The system is read-only, integrates without replacing the controls and can usually be installed without stopping production.