The Need
Our customer, a leading global manufacturer of spices was struggling in its factory, with inefficient monitoring and optimization of utility consumption, which negatively affected both operational efficiency and profitability.
The customer required a scalable Utility Management System (UMS) that could provide real-time monitoring, performance metrics, and actionable insights. The system also needed to integrate seamlessly with existing infrastructure and support future Industry 4.0 initiatives.
Impacts Delivered
- Considerable (more than 23%) reduction in annual energy Cost.
- Operational Efficiency - over 80% reduction in manual monitoring efforts.
- Savings on Maintenance - Reducation in unplanned downtime especially of AHU, due to HEPA filter rupture or clogging (which is very critical for quality product) by 25% and extended the lifespan of critical equipment. This resulted in significant savings on emergency repairs and replacement costs
Our Solution
Discovery Phase
- Gadgeon conducted a thorough site survey, analyzing existing infrastructure and identifying key monitoring points across various utility units.
- This phase ensured a tailored solution design aligned with the customer’s specific needs.
Custom Solution Design
- We leveraged our Delpheon IoT platform, in architecting a scalable UMS incorporating rugged industrial grade sensors, secure network infrastructure, and advanced analytics capabilities.
- The design focused on modularity and future expandability.
Phased Implementation
- The solution was rolled out in stages, prioritizing high impact areas.
- This approach allowed for iterative refinement and minimized disruption to ongoing operations.
- Each phase included rigorous testing and user acceptance procedures.
Continuous Optimization
- Post-implementation, Gadgeon provided ongoing support and optimization services, ensuring the UMS evolved with the customers changing needs and leveraged the latest technological advancements.
Key Components of the UMS system
- Industrial-grade sensors - Over 95 specialized sensors were deployed across the facility, capturing data on temperature, pressure, flow rates, and energy consumption of critical utility units including chillers, compressors, and boilers.
- Secure Network Infrastructure - A private LAN utilizing existing fiber optic infrastructure ensured reliable and secure data transmission.
- Delpheon IoT Platform - Gadgeon's proprietary Delpheon platform served as the core of the UMS, providing robust data processing, storage, and analytics capabilities.
- Advanced Analytics Engine - Custom-built analytics modules processed the influx of sensor data,, generating actionable insights, predictive maintenance alerts, and performance optimization recommendations in real-time.
Real-Time Monitoring and Alerting - Components.
- Data Collection – capturing of sensor data at sampling rates optimized for the unit.
- Processing and Analysis – At Edge computing
- Visualization – Custom dashboards & reports
- Alerting – SMS, Email, Push notifications.
- Data forms – for manual collection and input.
Scalability is achieved through:
- ERP Integration
- Modular Architecture
- API-First approach
- Cloud-readiness
Tools & Technologies
- Gadgeon’s IoT Solution platform – Delpheon
- Custom designed and Developed hardware units:
- Delpheon Gateway
- Delpheon IO Module
- Integration with Ramco ERP systems
