Remote Monitoring & IoT · MI-RM-02
Machine Energy Monitoring
Per-machine kWh, idle vs. run power profile, and a cost-per-shift view for three machines.
Remote Monitoring & IoT · MI-RM-02
Wireless energy meters with split-core CTs on three machines, a DIN-rail gateway, and a dashboard that shows kWh per machine, idle versus run power, and cost per shift.
- ₹46,800pilot BOM · hardware only
- 3 – 4 daysto a live pilot
- Starterintegration level
- 3validated providers
Why one meter for the plant hides the waste
The problem
The plant has one electricity bill and forty machines. Nobody can say which compressor is wasting power on idle, which shift runs the paint line inefficiently, or what a single part actually costs in energy. Energy-saving projects stall for lack of a baseline.
- A single plant-level meter hides per-machine waste
- Idle running — compressors, chillers, conveyors left on — is invisible
- Cost-per-part and cost-per-shift are estimates, not measurements
- ISO 50001 and customer sustainability audits need machine-level data
The solution
A wireless three-phase energy meter with split-core CTs clips onto each machine's incoming supply without a shutdown. Readings go via LoRaWAN or Modbus to a gateway and a dashboard that shows live kW, kWh per shift, an idle-versus-run profile and a cost view per machine.
- Per-machine kW, kWh, power factor and cost, live and per shift
- Idle-power profile exposes machines left running between jobs
- Alerts on abnormal consumption or power factor
- Baseline for ISO 50001 and energy-saving business cases
Validated service providers
Validated by TwoElectrons and ranked by validation score: verified credentials, completed jobs on the platform and client ratings.
- Sample Provider A — Pune · LoRaWAN sensing & dashboards · ★ 4.8 · 14 jobs
- Sample Provider B — Bengaluru · Energy & utilities IoT · ★ 4.7 · 11 jobs
- Sample Provider C — Coimbatore · Plant environmental monitoring · ★ 4.6 · 8 jobs
Provider listings are samples pending live registrations.
Pilot BOM and cost
Reference hardware to run the pilot. Unit costs are indicative Indian market prices for the component class.
| Qty | Item | Unit cost | Line |
|---|---|---|---|
| 3× | Wireless 3-phase energy meter split-core CTs, LoRaWAN or Modbus | ₹11,000 | ₹33,000 |
| 1× | LoRaWAN / Modbus gateway DIN-rail, 24 V | ₹12,000 | ₹12,000 |
| 1× | Industrial 24 V DIN PSU | ₹1,800 | ₹1,800 |
| 1× | Cloud dashboard energy widgets, per-machine | Free tier / open source | — |
| Pilot BOM total | ₹46,800 |
POC BOM cost only — hardware for a pilot. Installation, integration and provider services are quoted separately. Request for Quote
How per-machine energy monitoring works
- Clip. Fit split-core CTs on three machines' incoming supply; no shutdown.
- Connect. Mount the gateway on a DIN rail; meters join over LoRaWAN or Modbus.
- Baseline. Run one week to capture run, idle and off profiles per machine.
- Act. Set idle alerts and review cost per shift with production.
Pilot architecture
3× Wireless energy meters (split-core CTs · 3-phase) → LoRaWAN / Modbus gateway (DIN-rail · 24 V) → Cloud energy platform (kWh · PF · cost) → Energy dashboard (per machine · per shift)
Three machines on one gateway; add meters for every machine you want in the cost model.
Business case: idle power, cost per shift, ISO 50001
Ranges are typical figures reported for this class of solution; your pilot establishes the numbers for your plant.
- 5 – 15% energy saved on monitored machines (typical from idle elimination and scheduling)
- Per shift cost visibility (measured, not estimated)
- Hours of idle running found per week (the usual first finding)
- 3 – 4 days to a live pilot (three machines, one gateway)
Who this is for: Plant and utilities heads, Energy and sustainability managers, Auto, engineering and foundries, Plastics and textiles, Any plant with compressors, chillers or large motors, ISO 50001 programmes.
Illustrative case study
Illustrative scenario · not a client reference
A plastic injection-moulding unit in Ahmedabad (illustrative)
Set-up. Meters on two moulding machines and the central compressor, one DIN-rail gateway in the MCC room, dashboard shared with the production and utilities heads.
What happened. The compressor was found running fully loaded through the lunch break and for 90 minutes after the last shift. A timer and a shutdown SOP cut its consumption by about 12% in the first month; the plant then metered all eight moulding machines to build a cost-per-part model.
- Pilot budget: ₹46,800 hardware
- Compressor saving: ~12% (month 1)
- Idle hours found: ~11 per week
FAQ
Do we need to shut the machine down to install the meter?
No. Split-core CTs clip around the existing conductors and the meter takes a voltage reference from the panel; a qualified electrician fits it in under an hour.
LoRaWAN or Modbus?
Both work. LoRaWAN avoids cabling across the plant; Modbus is a good fit inside a panel that already has a gateway. The kit supports either.
Can it feed our BMS or ERP?
Yes — the platform exposes MQTT and REST; a scale-up phase typically pushes kWh per job into the ERP for cost-per-part.
What does the ₹46,800 cover?
Three meters, a gateway and a DIN power supply on a free-tier dashboard. Electrical installation, integration and provider services are quoted after a Request for Quote.
