Case Study · Food-grade plastics · A food-grade plastic manufacturer · Kizad Khalifa Industrial Zone, Abu Dhabi, UAE

Smart energy management for a food-grade plastic manufacturer

A 105,000 sq ft shop floor burning roughly 100,000 units of electricity per month on target equipment, with no handle on per-product-line consumption and excessive scrap-and-remelt of virgin plastic. SEnergy IoT disaggregated the energy, surfaced the waste, and gave shareholders a clear expansion roadmap.

6–8%
Annual production cost reduction
105K
sq ft shop floor instrumented
Per-line
Energy visibility by product & shift

The challenge

  • Unknown production energy rationalisation — no view of energy consumed per kg of plastic.
  • No handle on power factor, harmonics, or other major electrical parameters.
  • No energy disaggregation at the product-line level.
  • No energy break-up by shift.
  • Excessive scrapping and remelting of virgin plastic driving up both material and energy cost.

Objectives

  • Reduce energy and maintenance cost.
  • Provide per-product-line and per-shift visibility of energy consumption.
  • Ensure efficient raw material usage.
  • Improve maintainability of production equipment.
  • Alert on threshold breaches to protect equipment safety.

What SEnergy IoT did

Site survey & instrumentation

A site survey identified the energy guzzlers across production. Smart energy meters and monitoring hardware were installed and networked to the SEnergy Cloud.

Per-line & per-shift reporting

Energy metrics were produced for each product line and shift. Automated custom reports were generated against those slices, with customised time-slot definitions for working and non-working hours.

Conservation metrics

Efficiency and conservation metrics were defined and quantified. Consumption, usage, and wastage patterns were analysed against baseline.

Operational closure

Ticketing-system integration was wired for alert tracking. Curative recommendations were provided for equipment health. A clear roadmap to energy efficiency was handed over.

Results

  • Overall production cost reduced by 6-8% per year.
  • Specific consumption quantified for each product line — the business now knows the energy cost built into each unit of output.
  • Eliminated the need for unfruitful and costly external energy audits.
  • Qualified for industry-specific energy conservation references.
  • Clear visibility of installed plant capacity vs current utilisation, giving the shareholders a road map for future facility and production line expansion.
  • Continuous engagement for cost cutting in AMC, energy, manpower, and raw materials.

Platform & integrations

Smart Energy Meters Modbus TCP Per-line Disaggregation Shift-based Reporting Power Quality Analytics Ticketing Integration SEnergy Cloud Threshold Alerting

Running a continuous-production plant? Let's talk per-line visibility.

30-minute walkthrough. Energy disaggregation by product line and shift for food, plastics, chemicals, and FMCG manufacturing.

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