Where are energy guzzlers hiding in my operation? That’s a question preying on the minds of many CEOs. The results of just one of thousands of studies conducted around the world reveal this: the German industry could save 44 percent of its annual energy requirement (410 of 940 TWh) with commonly available energy efficiency technologies – without having to accept production limitations, according to an investigation by Hochschule Niederrhein. 410 TWh, the researchers say, equate to the output of roughly eight coal-fired powerplants.

Best-practice example from the packaging industry

Smurfit Westrock, a global leader in the field of paper packaging production, significantly optimized its energy consumption nine months after rolling out an efficient energy management tool. Specifically in terms of numbers that means 57 percent less electric power consumption outside of production hours. How did the Irish-American company manage to do that? The answer is: by implementing Schaffler’s Power-Adapt energy monitoring solution.

Smurfit Westrock was seeking a solution that not only captures but continuously monitors and analyzes energy consumption on factory floors.

Power-Adapt is flexibly usable and aside from becoming a new installation can be seamlessly integrated into existing energy management systems or combined with other solutions such as facility management systems. LoRaWAN (Long Range Wide Area Network) technology reliably transmits information through thick walls and across long distances, ensuring dependable data transfer. The results can be viewed immediately in a user-friendly, web-based interface.

Power-Adapt issues warnings in case of abnormal consumption levels

In addition to measuring power, gas, and water consumption, ambient variables such as temperature, humidity, and CO2 concentration can be captured via sensors. By monitoring base loads and peak levels Power-Adapt generates warnings enabling fast responses to abnormal consumption levels.

In addition, the system aggregates data from various devices to analyze the efficiency of processes and infrastructure. This information is essential for making well-founded decisions concerning a further optimization of operational processes, enabling companies to achieve cost savings while reducing their CO2 emissions at the same time.

In view of the successes achieved by the rollout of Power Adapt, Smurfit Westrock is planning to implement the system from Schaeffler in seven other French plants.

“We can see energy costs directly in black and white on our Power-Adapt dashboard and take appropriate measures for improvement. Having all energy data and data from other sensors or sources at a glance is really great.”

Lionel Bernard, Project Manager France at Smurfit Westrock

Interested readers can find additional information on Schaeffler’s Lifetime Solutions portfolio here.