Automotive

Saving ₹17.5 Lakh/Year for a Haryana Foundry with EMS

Share:

Executive Summary

A large manufacturing company in Faridabad, spending ₹15 crore annually on energy bills, faced challenges in managing their energy use. Energeia’s Energy Monitoring System (EMS) led to ₹17.5 lakh in savings, 188 tonnes of  CO₂ reduction, and higher machine uptime.

Key Stats

₹0.5 Lakh

Monetary Savings Annually

0,19,000 kWh

Energy Savings Annually

0 Tonnes

CO₂ Emission Reduction

Customer Overview

Established in 1982, a prominent manufacturing company specializes in producing Grey Iron, Ductile Iron, and SiMO machined castings, crucial for the automobile and other industries. With a connected load of 4 MW, the company incurs annual energy costs between Rs. 14.4 – 18 crore.

The Challenges

Operating in an energy-intensive industry, the company faced significant challenges in managing its energy consumption. The key issues included:

  • Inability to meet Specific Energy Consumption targets per tonne of metal produced.
  • Lack of remote monitoring, leading to accountability issues among production workers.
  • Difficulty in tracking daily energy consumption variations.
  • Reliance on manual metering, prone to human errors.
  • Absence of a system to monitor the time cycle of each batch of heat.

Energeia’s Solution:

Energeia implemented a comprehensive Energy Monitoring System (EMS) at the facility. The key components of this solution included:

Energy Monitoring System (EMS)

  • Installation of Energy Sensors: Various energy sensors were installed to provide continuous data streaming to Energeia’s servers.
  • Dedicated Dashboard: A dedicated dashboard was developed for the maintenance team to monitor energy usage in real-time and identify areas of high or unusual consumption.

Financing Model

The project was executed under a subscription business model, featuring:

  • Complete financing of the hardware infrastructure by Energeia.
  • Shared savings from retrofit solutions between Energeia and the company.
  • A monthly Software as a Service (SaaS) fee paid by the company for data point monitoring on the EMS.

Results

  • Annual Energy Savings: Achieved energy savings worth ₹17.5 lakh, lowering specific energy consumption by 45.6 KWH/Tonne on average.
  • Predictive Maintenance: Breakdowns were identified earlier, enabling predictive maintenance of all machines under monitoring.
  • Cycle Time Monitoring: Individual furnace cycle time started being monitored, reducing the occurrence of longer cycle times in a specific furnaces.
  • Project Expansion: Phase 2 of the project was sanctioned, with the machine shop coming under the EMS platform as well.

 

Let's Connect

Ready to reduce your energy and fuel bills?

Sankriti Malik

Head, Marketing & Growth

Sankriti is a dynamic growth catalyst, turning customer insights into impactful strategies.

She’s held multifaceted roles at high-growth startups like Kodo Tech, Athena Education, and Hora.AI, where she drove initiatives in product management, UX research, and branding. She’s also contributed to strategy roles at Indian Oil, Times Internet (BCCL) and The Copenhagen Post.

A Psi Chi Honors graduate from Wesleyan University in the US, Sankriti blends her expertise in UX design, data, and strategy to lead Energeia’s marketing efforts – always keeping the customer at the heart of her work. 
 
She’s passionate about gender equity in climate tech and actively contributes to networks like Leap.club and Ladies Who Lead. Her commitment to impactful digital design led her to join communities like GrowthX, IxDF, and Terra.do. In the past, she’s been a Fellow at the Patricelli Center for Social Entrepreneurship and co-founder of the Design Think Tank.