Advanced Energy Management: 136 Meters Digitized, 500k+ Daily Data Points (Leading Coatings Manufacturer)

@Faclon Team

November 14, 2025

2min read

About the Company

A leader in the coatings and paints industry with $2.49 billion market cap as of 2024, building a legacy of innovation and quality spanning over a century. The organization operates across diverse business verticals including decorative paints, industrial coatings, automotive coatings, and powder coatings with manufacturing facilities spread across multiple regions. With 3,700+ employees across all business verticals, the company focuses on implementing Industry 4.0 and IIoT solutions to enhance energy management, optimize operational costs, and achieve greater sustainability across its extensive manufacturing operations.

Problem Statement

Critical operational challenges threatening manufacturing efficiency

Limited energy visibility Energy consumption tracking restricted to main incomers of major sections with minimal traceability of consumption across downstream processes and equipment
Complex specific energy analysis Difficulty calculating and benchmarking specific energy consumption metrics for producing batches of goods with varying quality and finish requirements
Reactive electrical maintenance Manual and infrequent tracking of critical electrical parameters including harmonics, power factor, and KVA leading to delayed issue identification
Fuel accountability gaps Manual fuel consumption tracking with limited accountability across multiple manufacturing processes resulting in operational inefficiencies
Manpower productivity burden Electrical teams adopting manual methods for electricity distribution and fuel consumption management creating significant operational workload
Cost optimization constraints Need to enhance energy efficiency, identify electrical maintenance opportunities, and optimize costs across substantial utility demands and multiple energy-consuming assets

How Faclon Solved the Problem

I/O Sense Platform: Comprehensive Industry 4.0 deployment for energy management and process optimization

Energy Monitoring System

Deployed plant-wide energy consumption tracking with bifurcation and monitoring of key parameters including kWh, power factor, and THD with automated anomaly alerts

Load Management Capabilities

Implemented transformer load distribution monitoring enabling control and management of maximum demand across manufacturing operations

Production Efficiency Analysis

Established tracking of SFC (specific fuel consumption), total fuel usage, and SPC (specific power consumption) from incomer to individual equipment level

Equipment Insights Platform

Configured monitoring of equipment power usage, run hours, and automated daily deviation alerts for faster fault resolution and maintenance optimization

Comprehensive Data Acquisition

Digitized 136 energy meters using ST-54 I/O Connect suite with 4G-based IoT gateways collecting data at 30-second intervals processing 500k+ daily data points

Multi-Level Dashboard Integration

Created master dashboards, PCC analysis dashboards, section analysis capabilities, and equipment-level analytics with structured visibility from main incomer to individual equipment

The Outcome

Comprehensive results across operational efficiency

136 energy meters digitized

Complete automation of energy data collection eliminating manual tracking requirements and providing comprehensive coverage across manufacturing facilities

500k+ daily data points processed

Massive scale real-time data processing capability enabling detailed analysis of energy consumption patterns and optimization opportunities

30-second data intervals

High-frequency monitoring providing immediate visibility into operational parameters and enabling rapid response to energy anomalies and inefficiencies

Automated data collection success

Replacement of physical meter data collection with automated systems resulting in years' worth of manpower productivity savings

Specific consumption monitoring achievement

Implementation of SPC and SFC tracking for various SKUs providing actionable insights previously difficult to obtain through manual methods

Structured energy visibility

Establishment of comprehensive energy distribution view spanning from main incomer to sections, processes, and individual equipment enabling data-driven decision making

Behind the Scenes

Advanced technical implementation and strategic deployment considerations

IoT gateway specifications

ST-54 I/O Connect suite with 24VDC power, 2-week data backup capability, IP67 rated panel boxes, 4G+LAN connectivity supporting 64 indexes for comprehensive data acquisition

Platform dashboard architecture

Master dashboard with plant-level KPIs including overall energy consumption, DG generation, grid contribution, solar generation, fuel consumption, utility consumption, power factor tracking

PCC analysis implementation

Power Control Centre dashboards providing overarching insights into power distribution areas, consumption across plant sections, and solar/DG generation with bifurcation capabilities

Section-level analytics deployment

Sectional dashboards with detailed SLDs showing live power distribution status, comparative analysis capabilities, and individual section drill-down functionality

Equipment monitoring framework

Equipment analysis dashboards tracking specific power consumption (SPC), run-hours vs consumption analysis, live data tables, and kWH bifurcation for all manufacturing equipment

Data processing and reporting system

n-premise server setup with comprehensive networking architecture enabling real-time monitoring, automated reporting, and stakeholder-specific dashboard customization for operational optimization

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