Cement Industry

We are serving major Cement Groups with their specific EMS requirements by overcoming the unique site challenges.

Cement-Industry

About Our Client

  • This Group has a consolidated capacity* of 29 Million Tonnes Per Annum (MTPA) & this unit has installed capacity 3.46 lac tons per annum.
  • This cement manufacturing facility that is one of the most energy efficient in the country with 5 stage suspension pre-heater, High Pressure Roller Press grinding for all materials & Quality control through X-ray analyzer.
  • They were in search of thetrust worthy yet user friendly solution for implementing the Energy Management Tool capable of integrating with process monitoring modules as well.

Takeaway

Effectively integrated EMS with other Software & helped to get uniformity for end users. The management is relying on this solution to take concrete decisions on implementing effective Production Planning & Proactive Maintenance Activities.

Food & Beverage Industry

A Food & Beverage Company trusts our EMS for the Preventive Maintenance Activities!

food_industry

About Our Client

  • The Company & its subsidiary operate in prominent Pizza brand with the exclusive rights for India, Nepal, Bangladesh and Sri Lanka. It is market leader in the pizza segment with a network of 1,227 Pizza restaurants across 273 cities in India.
  • Its promoters are also equipped with the world’s leading baked goods & coffee chain, selling more than 1 billion cups of coffee a year and more than 3 million customers per day. The Company has 31 baked products restaurants across 10 cities in India.
  • Earlier they much relied to maintain the data logs manually which resulted to inefficient plant operating conditions & restraint users from taking any proactive measures for improvements.

Takeaway

GreenErgy provided a smart approach to the traditional maintenance methodology. The advanced system supported in preventive maintenance by reducing the downtime 25% and assisted in predicting the maintenance schedule for motors, compressor, chillers and other critical equipment.

Automotive & Beverage Industry

We are serving many Automotive Giants & major Auto ancillaries with our versatile-customized EMS installed at their multiple plant locations.

About Our Client

  • The Rs. 900 Billion Group of Companies which is having dominance with its Commercial, Passenger & Agricultural Vehicles over Indian Roads.
  • At this facility; it’s the Vehicle Assembly & Manufacturing unit comprising of Paint Shop, Machining Shop, Stamping Division& Assembly Lines.
  • Wanted to get the consolidated data by monitoring the Steam, Water & Energy Consumption over a single platform.

Takeaway

Developed a Customized GreenErgy EMS Suit for integrating the PLCs, Controllers, Flow Meters & Energy Meters over a single platform giving a precise Plant Operational Overview. This enabled users to undertake corrective measures & achieve around 24% savings.

A Group of Company benefitted with our Overall Equipment Efficiency (OEE) Solution

We also develop the customized OEE solutions considering the unique plant set up & distinguished industrial sectors.

About Our Client

  • It is Group is in the League of Fortune 500. Anchored by an force of over 1200,000 employees belonging to 42 nationalities with businesses ina wide range of sectors – metals, textilies, carbon black, telecom and cement.
  • The Machineries includes Mills, Mixers, Kneaders, Attritors, Tanks, Dispensers, Chiller, Compressors, Motors, etc.
  • The issue was that; the Management was unable to get the Real-time overview of Machine Running Conditions & Overall Production Status. This accounted for lesser productivity & unnecessary production delays.

Takeaway

End users could effectively plan preventive maintenance & achieve Guaranteed Machin uptime. The solution provided gave a Real-time Plant Operational Overview coupled with pragmatic & concise reports that connect with client’s continuous improvement strategy.
With this solution, operators and managers proactively improved the effectiveness in the production processbased on actual data and shredded the production cost by 2% in just one month post implementation of OEE.

Government Company

GreenErgy is awidely appreciated & trusted EMS tool for many Government owned companies in India over the years.

About Our Client

  • The Client is a public sector undertaking (PSU) under the Government in India.
  • It is the largest electricity distribution utility in India &2nd largest in Asia.
  • It supplies electricity to a staggering 25 million consumers. There are about 18.1 million Domestic Residential (72.4%), 4 million Agricultural (16%), 1.7 million commercial (7%) and0.346million industrial consumers (1.8 0%) who fetch an Annual Revenue of about Rs.500 million.
  • To address such Huge requirements & ever increasing demands; the strict policies needs to be defined. But for implementing these policies; monitoring the consumers with Effective Tools became the primary requirement.

Takeaway

Based on the system generated reports of harmonics upto 21st level, the consumers worked on the processes and systems that generated harmonics in the grid.
The harmonic level was reduced by 5% after six months of installation. Similarly, T&D losses calculated were reduced by 10% that had huge impact on cost for the utility company.

Steel Industry

Many Steel Industries are getting benefitted with our Customized & Scalable EMS Solutions.

About Our Client

  • It isan integrated steel producer with an annual capacity of 10+ million tonnes with a strong presence in intensive steel consuming markets.
  • This manufacturing dacility is 30 years old & comprises the ore beneficiation, pellet marking, iron making, steel making, and downstream facilities including cold rolling mill, gavansing, pre-coated facility, steel processing facility.
  • As it was an old facility; they were unable to keep track of their Energy Losses, Identify Inefficient Machineries & suffering from frequent Breakdowns. Also, it was hard to identify the Heat Per Ton calculations.

Takeaway

7+millions of kWH/Day energy supervised & 5000 kWH/day unit saved. Preventive maintenance helped cut down equipment breakdown by almost 25%. The Customized provision for Production Data Integration made things easy for keeping track of Specific Energy Consumption.

Paint Industry

We are serving many Pigments, Paints & Coatings Manufacturers to visualize their facilities with Real-Time Operational Parameters.

About Our Client

  • A Global leader in paint manufacturing with 40 production sites in 24 countries, and presence in over 100 countries, Matrix organization divided into seven segmentssellingdecorative paints and performance coatings for marine, powder, and protective coatings.
  • This facility includes equipment such as extruder lines, mill lines, PlasMecmixer, shot blasing, zepline blender, etc.
  • But being unable to get the exact Machine Run Hours, Machin Loading patterns; they often missed their Production & Product Costing targets. Also the Ghost Loads during non-productive hours were haunting them.

Takeaway

Successfully helped save energy consumption by 18% & improved Production by taking informed decisions with EMS. Our EMS is effectivelymonitoring the Machine Run Hours, Specific Energy Consumption Reports gives the precise operational overview & helps to achieve relevant targets.

Pharma Industry

We are serving many leading Pharma Companies to ensure the Health of their Facilities.

About Our Client

  • A leading Indian Pharmaceutical company which is a fully integrated, global healthcare provider.
  • It caters with formulations, APIs, vaccines, biosimilars, complex products, animal health products as well as wellness products.
  • But using conventional manual efforts for their load monitoring led to gather inaccurate information. This made things difficult to undertake firm decisions for plant improvements.

Takeaway

GreenErgy helped them to set the Performance Benchmarks on Cost Centers & made way for further Improvements. Effectively implemented Customized reports to easily evaluate & compare the various Cost Centers at Plant Process.

Malls, Hotels, Commercial building

We are helping out Commercial Facilities such as Malls, Hotels, Shared Spaces, etc. by simplifying the complex tenant Billings & make it a Fair Deal.

About Our Client

  • One of the company’s offices is a tower, which is a ground plus ten-level office.
  • It is constructed on a 1.5-acre site, having a built-up area of 32,800 square meters. It includes an expansive, double-height, motorbike showroom on the ground and offices on each floor.
  • Though the facilities shared the common loads, our Automated Bill Generation has helped to streamline the Accurate & Faster Bill Payments without any conflicts.

Takeaway

7+millions of kWH/Day energy supervised & 5000 kWH/day unit saved. Preventive maintenance helped cut down equipment breakdown by almost 25%. The Customized provision for Production Data Integration made things easy for keeping track of Specific Energy Consumption.

Casting Industry

We are saving the MD Penalty charges at a renowned Casting Industry.

About Our Client

  • This is a leading Gray & Spheroidal Graphite (DuctileIron) Casting manufacturing company which manufactures all grades of Grey & S.G Iron castings.
  • It is serving major automotive, Agriculture, Earthmoving and Engineering Industries across the Globe with its 61000MT / Annum production capacity.
  • It houses following Process & Operations: Moulding, Core Making, Melting, Poring & Machining Due to varying production cycle of furnaces; client was being heavily penalized over MD overshoot as a major problem.

Takeaway

Our EMS has helped to arrest the MD Overshoot Penalties which has majorly contributed the direct savings over their monthly Energy Bills upto INR 0.4 million/Month.
Also, with Accurate Load Monitoring, Customized Reports, Identification of Ghost Loads & Powerful Analytics has ultimately led to achieve 21% energy savings.