atcetera GmbH - manageENERGY - energy monitoring

atcetera managENERGY
Energy monitoring

ISO 50001 – ENERGY MANAGEMENT

managENERGY is an eligible energy monitoring system according to ISO 50001!

The energy monitoring system manageENERGY according to ISO 50001

Efficient energy management with the energy monitoring system managENERGY

In times of rising energy costs and increasing environmental requirements, efficient energy management is crucial for the economic success and sustainability of companies. The innovative energy monitoring system managENERGY from atcetera offers a tailor-made solution to monitor, analyze and optimize your energy consumption data in real time. With this powerful tool, companies can not only reduce their energy costs, but also reduce their carbon footprint and comply with legal requirements.

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What is managENERGY?

managENERGY is an advanced energy monitoring system that enables comprehensive monitoring and analysis of a company’s entire energy consumption. By precisely recording energy flows and visually processing the data, you gain in-depth insights into the energy use of your buildings, machines and systems. This allows you to quickly identify inefficient areas and take targeted optimization measures.

Main functions of managENERGY

Real-time monitoring of energy consumption

managENERGY offers live data visualization that makes it possible to monitor energy consumption at any time and any place. This promotes a better understanding of actual energy requirements and provides a transparent basis for energy optimization decisions.

Automated reports and analyses

With managENERGY, you can create individual reports that provide detailed analyses of your energy consumption. This helps you to identify trends, forecast consumption and take targeted measures to make savings.

Recognizing and exploiting potential energy savings

By comprehensively analyzing consumption data, managENERGY identifies areas with high savings potential. Automated alarms warn you of unusual consumption peaks so that you can intervene in good time.

Compliance with legal requirements

managENERGY helps you to comply with energy efficiency guidelines and legal requirements (such as the EDL-G). With precise data and comprehensible reports, you are ideally prepared for audits and certifications.

Analyze energy consumption in different areas

Whether lighting, air conditioning systems, machines or industrial processes – managENERGY enables the detailed analysis of energy consumption in all areas of your company. This supports well-founded optimization and long-term cost reduction.

Dashboard

On the visualization, each production section is colored according to its current energy rating in a graphical plant overview. Thus, it is visible at a glance if there is a change in SEUs in an area.

The press monitor in energy monitoring

In feed production, the pressing of the feed (pelleting) represents the process with the highest energy demand.

With the press monitor, the current energy consumption in the form of electricity and steam, the relevant machine data and thus the live energy key figures of the pressing process are continuously determined in real time and compared with historical data from the system database. The result is displayed live to the operator in the machine control system as key figures, cost factors and also as a traffic light function.

He can thus continuously adjust the machine parameters optimally during the process in order to proactively produce more energy-efficiently. This function can be transferred to other energy-intensive processes in automated production. The press monitor in particular has already been tested in several feed mills and led to a significant stabilization of the key figures during operator changes and thus also to energy savings. Several plant managers spoke of the awakened “play instinct” of the millers to produce as efficiently as possible.

The additional historical evaluation that is available also enables the mill management to react to tendential changes in the plant.

The mill monitor in energy monitoring

Grinding is another energy-intensive process in feed production.

This process is automated to the greatest possible extent. By continuously determining the relevant key figures, by means of energy measurement technology, the machine data and the historical data on the current product in the plant, predictive maintenance can be derived. Attention can be drawn to signs of wear, such as clogged filters or worn beaters, in order to prevent negative effects on the efficiency of the plant. This feature provides mill metrics that indicate the optimal time for maintenance. Phases of inefficient grinding with worn tools or too early tool changes are thus avoided.

The compressed air monitor in energy monitoring

Compressed air represents a significant cost factor in almost all industrial plants. Modern, efficient compressed air systems have already been installed in many plants. However, there is a need for clarification on the factor leakage losses and the associated cost trap “compressed air waste” due to leakage. Continuous monitoring by the energy monitoring system managENERGY can prevent this cost trap efficiently and without time-consuming searching. In adjustable intervals during the plant shutdown, the customer’s plant is pressurized in order to record the energy consumption at the compressor and the compressed air volume flow to the individual plant parts.

The following can be derived from the measurement results of our energy monitoring system:
Occurrence of a new compressed air leak
Local containment of the leak
Extrapolation of the leakage loss
Automated fault reports

The base load monitor in energy monitoring

The base load accounts for a not inconsiderable share of the energy costs. All plant components that consume energy even when the plant is inactive make up the base load. Since these plant components are in operation 24 hours a day, 7 days a week, they quickly represent a considerable cost factor. In new plants, this factor has already been minimized by modern automation. In older plants, energy consumption continues to add up to over 100 kw due to rebuilds, expansions, and only partially automated areas.

The base load monitor determines the energy consumption of all plant sections during each plant shutdown and automatically sends a report to the responsible authority.

The following can be derived from the results of the energy monitoring system managENERGY:

Energy consumption of all plant components
extrapolated costs
changes in the base load

The plant management is thus able to recognize any continuous consumption and to counteract it with appropriate measures. Misbehavior in non-automated areas can also be quickly detected and avoided by the manageENERGY energy monitoring system.

Peak load management in energy monitoring

The peak load management in manageENERGY provides the following additional modules to the conventional systems:

a static load cut-off in stages
a grid-dependent management with configurable location-relevant blocking and free times
an interface to plant automation for process-dependent load control.

In case of need, the first area to be throttled is the one that currently has the least influence on the output of the production process. The available load window can thus be optimally utilized without having a significant negative impact on the process chain.

Alarming

Based on the realization that in production plants the focus is always on the product to be manufactured, its quality and the performance of the plant and not primarily on the energy efficiency, a comprehensive evaluation and alarm system was developed.

In the background, key figures are continuously determined from all the data obtained from the energy measurement technology, the plant control system, the ERP system and other measured variables, and compared with historical data or other dynamic limit values in order to automatically notify the defined person responsible for the relevant area if action is required. This always ensures that changes in the plant that result in a reduction in efficiency can be dealt with promptly. Faults in the measurement infrastructure are also detected and alerted immediately.

Reporting

In addition to reports that support the work of the energy management team according to ISO 50001, the main focus is on providing production with a tool to determine the optimal configuration of the individual production sections for each article.

In the production report, the energy consumption is shown for each individual batch in each individual production section, the corresponding key figures under the corresponding machine parameters. This makes it possible to show for each article under which parameters in the individual processes the highest efficiency can be achieved.

The energy cost shares of each product can thus also be determined for each part of the process chain.

Why invest in energy management?

Cost reduction through targeted energy optimization: With the detailed analyses and real-time data from managENERGY, energy-saving potential can be identified and costs sustainably reduced through targeted measures.
Sustainability and CO2 reduction: By continuously monitoring and optimizing energy consumption, your company makes a valuable contribution to environmental protection and the reduction of CO2 emissions.
Compliance with legal requirements: managENERGY makes it easier to comply with regulations and helps you prepare for energy audits and certifications.
Easy implementation and integration: The system can be flexibly integrated into existing IT infrastructures and is suitable for both small and large companies.

Conclusion: Energy monitoring for the future

In a world where energy efficiency and sustainability are becoming increasingly important, the energy monitoring system managENERGY from atcetera is an indispensable tool for any automated manufacturing company. The comprehensive monitoring, detailed analyses and continuous optimization of energy consumption help you to reduce your energy costs, meet legal requirements and make a positive contribution to the environment at the same time.

Start into an energy-efficient future now – with the energy monitoring system managENERGY from atcetera!

Testimonials

“For us, sustainable work processes and energy-efficient production processes have top priority. The Manage Energy energy controlling system from atcetera gruppe supports us in optimizing and expanding our innovative environmental policy. A sensible investment for anyone who wants to uncover energy saving potential in their company.”

Volker Ollmann Process optimizer and energy manager ATR Futtermittel–ATR Landhandel GmbH & Co. KG

“Our guiding principles in the area of environmental protection are environmentally oriented and forward-looking action and energy-efficient production conditions. In this context, our innovative corporate management attaches great importance to environmentally friendly and responsible work. The establishment of the eligible energy controlling system Manage Energy of the atcetera group supports us in continuously developing and optimizing our production processes in line with our environmental policy.”

Daniel EibischMaintenance & Project Manager–Radsystem GmbH

atcetera managENERGY