SOLVERA LYNX CASE STUDY
IMPLEMENTATION OF A COMPREHENSIVE ENERGY MANAGEMENT SYSTEM
A manufacturing company in Serbia operates a large industrial complex with energy-intensive processes, where stability, reliability, and visibility into energy consumption have a decisive impact on costs and productivity. Before system implementation, the company primarily relied on aggregated data, without clear insight into which machines, processes, or facilities were generating inefficiencies and deviations.
PROJECT OBJECTIVES
- Gain full visibility into electricity, gas, water, and heat consumption
- Establish an early anomaly detection system
- Create a data-driven foundation for optimization and cost savings
KEY CHALLENGES BEFORE IMPLEMENTATION
SOLUTION: IMPLEMENTATION OF A COMPREHENSIVE ENERGY MANAGEMENT SYSTEM WITH GEMALOGIC
The solution is built on three interconnected pillars that provide full visibility into energy flows across the industrial complex. The system integrates advanced metering equipment, a centralized analytics platform, and end-to-end transparency—from utility billing points to individual machines.
KEY DATA INSIGHTS
Energy Consumption by Source – The Complete Picture
Understanding the energy structure
The chart illustrates the distribution of consumption by primary energy sources across the industrial complex. Electricity accounts for 74% of total consumption, clearly indicating where the greatest optimization potential lies:
- Electricity: 74% – primary energy source
- Gas: 15% – secondary source
- Heat: 10% – partial consumption and distribution losses
This insight is essential for defining optimization priorities and directing investment resources effectively.
Annual Energy Consumption Trends by Source
The chart clearly illustrates seasonal fluctuations in electricity and gas consumption, with increased activity during the summer and autumn months due to cooling demand and intensive production. A year-round overview is essential for KPI planning, energy demand forecasting, and future capacity planning.
ANOMALY IDENTIFICATION – COMPRESSOR CASE STUDY
Hidden Inefficiencies in Equipment Operation
The chart reveals pronounced compressor cycling patterns and irregular operating rhythms, indicating excessive energy consumption during periods of reduced or idle production. This represents a typical example of “hidden costs” that often remain unnoticed without detailed monitoring.
CONSUMPTION BY EQUIPMENT – MAJOR ENERGY USERS
Overview of Key Loads
Analysis of consumption by individual equipment reveals the main load drivers and enables targeted optimization measures:
- Extraction system: 48% – largest consumer
- Compressor: 25%
- Conveyor line: 13%
Based on these findings, the company can:
- Optimize extraction system operation and settings
- Assess production line efficiency
- Reduce unjustified operating hours of critical equipment
ADVANCED OPERATION MONITORING – HEATMAP ANALYSIS
The heatmap visualization displays machine operation by hour and day throughout the month, enabling quick identification of operating patterns. It is particularly valuable for diagnostics, showing when, how much, and why equipment consumes energy.
This makes it possible to rapidly detect operating rhythm deviations, nighttime or weekend operation, and periods of excessive consumption. Heatmap analysis enables immediate corrective actions and improved process efficiency.
ACHIEVED RESULTS
By implementing the energy management system, the company gained comprehensive control over energy flows, enabling long-term optimization, cost reduction, and accurate investment planning.
Industrial processes have become too complex to manage without precise energy data. By integrating metering, communication, and real-time analytics, companies gain full control and the ability to make fast, reliable, and cost-effective decisions.