Discover how Ecolibrium partnered with a leading global Cold Drawn Welded (CDW) precision tube manufacturer to achieve significant SEC reduction in manufacturing and optimise energy consumption and reduce emissions at their Chennai plant using Ecolibrium’s SmartSense, our AI-powered decarbonisation platform. By minimising idle time and leveraging advanced data science, this solution drives significant energy efficiency improvements and supports sustainable manufacturing. Explore how Ecolibrium’s SmartSense can elevate your energy management efforts. 

Outcome summary  

• Delivered up to 11% SEC reduction for large process equipment.  

• Achieved an average 2.5% reduction in carbon emissions. 

Challenges faced 

The challenges included high energy consumption in auxiliary equipment, persistent idle running, limited data-driven insights, and pressure to reduce costs and emissions. 

The Solution  

Implementing Ecolibrium’s SmartSense transformed workforce productivity by providing the on-ground team with real-time, data-driven insights for greater efficiency. New SEC baselines for each product reinforce our commitment to ongoing energy efficiency and sustainability. Monitoring 260 integrated energy meters across one facility tracks energy use, idle time, and SEC benchmarks at the equipment level, including compressors, cooling towers, welders, and tube processing machines. The solutions implemented focus on Operational Excellence, Energy Management, and Overall Equipment Effectiveness (OEE). Which ultimately leads to driving a higher SEC reduction in manufacturing units.

The Outcome  

Ecolibrium’s SmartSense, using 260 energy meters, cut auxiliary equipment’s excess energy by 16% (even idle), reduced SEC by 11.1%, and saved 4% via VFDs for compressors. Precision tube manufacturing saved 7.14% annually; CDW tubes saved 1.1% by eliminating idle running; ERW tubes saved a combined 3.02% with VFDs. Phase one delivered 3.78% plant-wide savings. Phase two, with Ecolibrium SmartSense reports, added 1.39% yearly savings, with some sections saving up to 2.25%. This built lasting trust and partnership. 

The Impact  

Ecolibrium’s SmartSense was rolled out at the Chennai facility, where 260 energy meters were installed to monitor key production areas. The system identified 16% excess energy use in idle auxiliary equipment, leading to the introduction of Variable Frequency Drives for compressors and pumps and the elimination of idle machine running significantly boosting overall efficiency 

Ready to unlock energy savings and elevate indoor air quality in your facility?  

Unlock the power of data-driven operations with Ecolibrium’s SmartSense designed to boost efficiency and sustainability for your facility. Schedule a demo today and start your journey toward smarter, more efficient building performance.