A leading Indian conglomerate with a footprint across 10+ industries set out to optimise energy monitoring across its multiple manufacturing facilities. The organisation needed a scalable, unified system to streamline data monitoring, reduce manual reporting, and drive cost savings through actionable energy insights. Ecolibrium’s SmartSense platform was deployed at 13 manufacturing plants, including major sites in Pune, Hyderabad, Chennai, and Vikhroli (Mumbai), to transform energy operations across plants and support long-term sustainability goals.

Outcome Summary

• $1 million saved across plants over 3 years.
  
• $5,000 annual savings via idling HVAC alerts.
  
• 70% reduction in unproductive hours through automation.

Challenges Faced

Fragmented energy monitoring systems created data silos across facilities, limiting visibility for the central energy team. Manual reporting delayed conservation efforts, and supervisors spent hours on routine data collection. The goal was to transition to a real-time, centralised Energy Management Information System (EMIS) to improve decision-making, eliminate inefficiencies, and support predictive maintenance.

The Solution

Ecolibrium deployed Ecolibrium SmartSense, integrating over 1,200 sensors and IoT gateways for live tracking of energy and utilities. What began as an energy monitoring upgrade expanded to cover water, steam, compressed air, gas, and Scope 2 & 3 emissions. The system allowed for predictive insights on HVAC and compressor performance, while EMIS reporting was fully automated and accessible from both plant and central teams.

Ecolibrium SmartSense analysed real-time data from 1235 sensors and monitored Compressors, Chillers, HVAC, Utilities, and Energy Meters. Operational excellence, energy management, digitised maintenance and asset CBM/PDM solutions were implemented to resolve the challenges.

The Outcome

The organisation achieved $1 million in cumulative cost savings, driven by enhanced energy optimisation, automation, and predictive maintenance. By identifying idle HVAC usage, the system enabled $5,000 in annual savings, while a compressor optimisation initiative unlocked an additional $8,000 in yearly savings. The platform also reduced unproductive person-hours by 70%, thanks to full automation of data collection and EMIS reporting. As the solution scaled, it expanded beyond energy monitoring to include utilities such as water, steam, gas, and compressed air, and enabled Scope 2 and Scope 3 emissions tracking, supporting both operational efficiency and the organisation’s carbon reduction goals.

The Impact

Ecolibrium SmartSense created a single energy and utility dashboard across all 13 plants, streamlining reporting and decision-making. Teams gained access to real-time insights on energy consumption, utility usage, and asset performance. Predictive maintenance tools reduced downtime and boosted equipment life. Scope 2 and Scope 3 emissions tracking allowed the organisation to take informed steps toward carbon neutrality, while saving costs and time through automation.

Looking to reduce energy spend and gain full control of your industrial operations?

Ecolibrium SmartSense helps manufacturers scale savings, reduce emissions, and automate decision-making with AI-powered visibility. Book a demo today.