As one of the world’s largest building materials suppliers and cement producers, the company has a global operation spanning across 50 countries. However, the company lacked the ability to properly monitor their energy consumption at the equipment level in real time. This lack of visibility led to delays in timely identification of performance issues, which led to increased downtime of machinery.
The company sought a user-friendly solution that plant managers could easily adopt and deploy at remote quarries to identify system performance issues in real-time.
Kambo’s official energy monitoring partner, Panoramic Power was selected for a pilot program where monitoring was installed at three locations within one of the company’s manufacturing sites. More than sixty device level sensors were deployed to monitor pumps, conveyors, and crushers.
By connecting energy to the company’s production goals with Panoramic’s granular data, the manufacturer was able to quickly identify system performance inefficiencies. Savings of $270,000 per year were realized through the identification of an inefficient conveyor motor that was constantly overloading and creating a bottleneck. Another $10,000 per year of savings was achieved through the reduction of off hour consumption at several buildings and plants.
Overall, these savings amounted to a return on the investment within just one month.
The pilot program improved system performance and increased productivity by 20%. These results paved the way for global deployment in phases to over 70 sites.