Smart Energy Monitoring for Process Plant

Real-time energy intelligence implemented for an FMCG process plant (NearbyShop) to optimize consumption, eliminate outages, and improve operational efficiency.

Client Overview

NearbyShop operates a high-throughput FMCG process plant with multiple production lines running continuously. Energy consumption forms a significant portion of operational costs, making efficiency and reliability critical to business performance.

Operational Challenges

Lack of real-time visibility into energy usage across production lines
Undetected load imbalances and peak demand spikes
High energy costs due to inefficient consumption patterns
Risk of unplanned outages affecting production continuity
No centralized energy monitoring or analytics platform

Energy Consumption Trend Graph

Solution Implemented

A comprehensive Smart Energy Monitoring solution was deployed across multiple production lines to measure, analyze, and optimize energy consumption in real time.

Energy Metering Network

Intelligent energy meters installed at feeder, line, and machine levels to capture granular energy data.

Real-Time Analytics

Continuous tracking of voltage, current, power factor, demand, and load patterns across all production lines.

Alerts & Protection

Automated alerts for overloads, phase imbalance, and abnormal consumption trends to prevent outages.

Energy Monitoring Dashboard Screenshot

Dashboards & Visualization

Line-wise and machine-wise energy consumption
Peak demand and load profile visualization
Energy cost analysis by shift and process
Power quality monitoring (Voltage, PF, Harmonics)

Measured Outcomes

17%

Reduction in Energy Consumption

0

Unplanned Power Outages

150+

Sensors & Energy Meters Deployed

Business Benefits

Lower energy bills through optimized load distribution
Improved power reliability across all production lines
Data-driven energy management and planning
Early detection of inefficiencies and abnormal consumption
Support for sustainability and energy compliance goals

Conclusion

The Smart Energy Monitoring implementation enabled NearbyShop to gain full visibility into energy consumption, eliminate unplanned outages, and achieve measurable energy savings. The solution supports continuous improvement and long-term sustainability for FMCG process operations.