The Challenge
Utilities like boilers, chillers, compressors, and furnaces are some of the most energy-intensive assets in a plant. They often run out of sync with production demand; boilers cycling when idle, chillers operating at part load, compressors running with leaks. These inefficiencies rarely appear in summary energy bills, but they steadily raise energy per unit produced.
Problems like poor chiller sequencing, boiler cycling losses, excess compressed air demand, or furnaces running at non-optimal setpoints can go undetected. These inefficiencies rarely show up in routine reports and are often mistaken for normal variability. Without analyzing utility performance alongside production conditions, most energy-saving efforts remain reactive or equipment-focused, instead of data-driven and targeted.
In energy-intensive industries such as cement, glass, food processing, and chemicals, these hidden losses translate into higher energy per unit produced and steadily rising operating costs.
The Solution with SIA
SIA focuses on uncovering efficiency gaps in utility systems by analyzing their operation in the context of real production demand. It learns from historical records of boiler usage, chiller cycles, compressor load variations, and furnace settings, correlating them with batch schedules, shift timing, and process conditions.
Rather than simply flagging consumption spikes, SIA identifies systemic mismatches such as utilities running idle during non-productive hours, part-load operation inefficiencies, or overcapacity in certain shifts. These insights are delivered in clear language, showing where adjustments to utility usage, startup timing, or load balancing can reduce energy waste.
Teams can begin by uploading logs, SCADA exports, or utility summaries. Live data feeds or sensor integration are optional, not mandatory.
Impact You Can Measure
- Lower energy use per ton, batch, or unit produced
- Detection of inefficient boiler, chiller, or compressor operation
- Alignment of utility load with production demand
- Improved coordination between operations and maintenance teams
FAQs
Yes. SIA can work with exported logs or SCADA summaries. You don’t need real-time integration to begin identifying inefficiencies.
Logs from boilers, chillers, compressors, or furnaces, along with batch production records, shift schedules, and temperature or pressure settings. Even periodic or manual records can provide meaningful insights.
Dashboards show total energy consumed. SIA explains how different operating conditions affect energy efficiency and provides recommendations to improve it.
No. You can start with existing exports or log sheets. If you already have an EMS or sensors, their data can be used without needing custom integration.
Real-World Example
In batch-process industries like food, beverage, and chemicals, plants often run chillers or boilers in anticipation of demand, leading to part-load inefficiencies. By analyzing time-stamped utility logs alongside batch and cleaning schedules, companies have adjusted startup and shutdown practices to better match production cycles. This has improved energy efficiency and reduced unnecessary equipment wear.