Outcome Summary
- Over 57% reduction in GHG.
- Saved 8831.6 tonnes of CO2 per year.
- 3% reduction in SEC.
- Optimised labour by 30%.
- Monthly cost savings of INR 1.2 L on the Kankroli plant’s electricity bill.
- Aims to become carbon neutral by 2050.
The Challenge
The client aims to be carbon neutral by 2050, prioritising energy savings and resource management. Previously, the team collected data manually, resulting in an increase in accuracy and errors. Seeking a comprehensive solution, they wanted to monitor equipment-wise power consumption and leverage predictive analytics for actionable insights, driving efficiency and automation across operations.
The Solution
Ecolibrium’s partnership with the client began in 2018 at their Kankroli plant, where Ecolibrium’s SmartSense™ was installed as a proof of concept on two transformers and two motors within 15 days. Within six weeks, energy consumption was substantially optimised. The solution was then scaled across the plant, with data from over 345 sensors routed daily to Ecolibrium’s SmartSense™ for specific power consumption (SPC) monitoring. This led to a customised tyre industry solution, with full project handover and staff training by late 2019. Implemented solutions included CO2 tracking, energy management, sustainability, digitised maintenance, and operational.
The Outcome
The client’s collaboration with Ecolibrium at the Kankroli plant resulted in a 57% reduction in GHG emissions over eight years and annual savings of 8,831.6 tons of CO₂. Specific Energy Consumption (SEC) was reduced by 3%, while monthly cost savings reached ₹1.2 lakhs. Additionally, labour efficiency improved by 30%, demonstrating significant progress in sustainability, cost control, and operational excellence.
The Impact
Ecolibrium’s SmartSense was deployed across all 8 plants (excluding Chennai), transforming energy monitoring and predictive maintenance from its initial proof of concept on 2 transformers and motors at Kankroli to over 1,800 sensors across sites today. The solution automates more than 30 daily reports on specific power consumption and asset energy usage, saving 4 hours of manpower daily through automation. Ecolibrium’s SmartSense also identifies anomalies and optimises power factor with timely alerts, driving efficiency and sustainability across operations.
Ready to boost efficiency and cut emissions like the leading tyre manufacturer? Connect with Ecolibrium to see how Ecolibrium’s SmartSense can transform your operations. Contact us today to book a personalised demo.
