Advanced Energy Management: 204 Nodes Digitized, 500k+ Daily Data Points (Leading FMCG Conglomerate)

@Faclon Team

November 14, 2025

2min read

About the Company

A multinational conglomerate with $56 billion market cap as of 2024, renowned as a leader with a ric h legacy spanning over a cen tury dedicated to excellence across diverse sectors. The organization maintains a strong presence in FMCG, agribusiness, and hospitality with world-class facilities and sustainable practices reflecting commitment to innovation and growth. With 36,500 employees across all business verticals, the company operates through multiple business segments including paperboards & packaging, hotels, and information technology, focusing on implementing Industry 4.0 and IIoT solutions to achieve higher levels of sustainability and operational efficiency.

Problem Statement

Critical operational challenges threatening manufacturing efficiency

Labor-intensive data collection Operators required to physically collect electricity, fuel, and compressor data by visiting individual feeders for main incomers, processes, and utility locations twice daily onto manual log sheets
Manual reporting burden Extensive manual effort required for report generation and data collection increasing operational workload and reducing team productivity across manufacturing operations
Reactive maintenance approach Electrical anomalies difficult to identify with handheld instruments causing hours-long source identification delays resulting in significant productivity losses
Limited decision intelligence Absence of adequate real-time visibility preventing teams from making faster decisions regarding fuel, energy, and utility consumption optimization
Visibility gaps across utilities Challenging for teams to gain comprehensive business insights on energy consumption across electricity, water, fuel, and compressed air systems
Scalability constraints Large-scale manufacturing operations requiring systematic approach to monitor and optimize multiple utility streams simultaneously for enhanced sustainability

How Faclon Solved the Problem

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

Automated Data Acquisition

Deployed ethernet-based gateways collecting data from 204 digitized nodes including energy meters, flow meters, DG Set PLCs, and level sensors with 30-second data intervals

Live Power Dashboards

Implemented real-time insights on power consumption, power factor, and harmonics across main-incomers, utility sections, and processes with comprehensive graphical analysis

Dynamic SLD Integration

Created dynamic single line diagrams of electrical, fuel, and water distribution enabling faster identification of working status and network threats

Event-Based Alerting

Configured event loggers with alert systems for teams to identify recurring transient events and take action based on frequent occurrences

Intelligent Reporting System

Established scheduled detailed reports (daily, weekly, monthly) for stakeholders from central to plant teams covering energy, fuel, production, and utility metrics

Comprehensive Platform Features

Integrated 60+ KPI dashboards, 15 dynamic SLDs, 10 custom report types with I/O Lens, I/O Forms, I/O Matrix, and Expression Resolver capabilities

The Outcome

Comprehensive results across operational efficiency

204 nodes digitized

Complete automation of data collection from energy meters, flow meters, DG controllers, and utility sensors eliminating manual data gathering requirements

500k+ daily data points processed

Massive scale data processing capability enabling comprehensive analysis of energy, water, fuel, and utility consumption patterns

30-second data intervals

Real-time monitoring capability providing immediate visibility into operational parameters and enabling rapid response to anomalies

60+ KPI dashboards delivered

Comprehensive visibility across electrical energy management, water treatment systems, fuel monitoring, and utility performance metrics

15 dynamic SLDs provided

Interactive electrical, water, and fuel distribution diagrams enabling faster identification of system status and operational threats

10 custom report types

Automated reporting system delivering scheduled insights to stakeholders eliminating manual report preparation and ensuring consistent data-driven decision making

Behind the Scenes

Advanced technical implementation and strategic deployment considerations

Hardware architecture specification

IoT gateways with 24VDC power, 2-week data backup capability, IP67 rated panel boxes, 4G+LAN connectivity supporting 64 indexes for comprehensive data acquisition

Multi-utility monitoring integration

Comprehensive coverage across electricity (HT/LT feeders, DG sets, solar), water (WTP, STP, ETP, drinking RO), fuel (LPG, HSD tanks), and utilities (boilers, compressors, chilled water)

Platform feature deploymentn

I/O Lens for no-code dashboard creation, I/O Forms for manual data collection, Reports with 15+ templates, I/O Matrix for drill-down analytics, I Scada for process flows

Electrical energy management system

Management dashboards with drag-and-drop widgets, MCC dashboards for individual motor monitoring, electrical SLDs showcasing live consumption from HT to equipment level

Water management architecture

WTP monitoring with source water consumption tracking, tank level monitoring, STP/ETP performance analysis, and interactive distribution network SLDs

Fuel and utility optimization

Real-time fuel level monitoring across HSD/LPG systems, boiler SFR tracking, compressor SPC analysis (kWh/CFM), and chilled water distribution management

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