Non-intrusive Power Monitoring Solution: About
21% Reduction in Power Consumption for 10
Machines with an Annual Saving of Around
50,000 Euros

Location：Automotive Production Facilities, Slovakia

Milesight Partner

Heliotics

Location

Automotive Production Facilities,
Slovakia

Applications

Energy Efficiency,
Smart Building

Devices Deployed

30pcs x CT10x

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BACKGROUND
CHALLENGES
SOLUTION
RESULTS
WHY MILESIGHT
PARTNER

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Energy Efficiency

Background

In the age of sustainability, transforming existing buildings into green and livable spaces has become a global imperative. Utilizing innovative technologies such as LoRaWAN® and IoT solutions, building owners and facility managers are spearheading initiatives to breathe new life into their buildings. Building owners have recognized the growing market demand for green buildings and the appeal of reducing energy consumption. The most common challenges to facility management energy monitoring include initial equipment costs, installation complexity, data quality and accuracy, system optimization, and information presentation.

Our partner Heliotic helps customers optimize energy efficiency by monitoring energy consumption across various industries. At the automotive production factories in Slovakia, Heliotic successfully deployed a non-intrusive power monitoring solution that significantly reduced energy consumption.

non invasive electricity monitoring solution factories

Challenges

Lack of Real-time Data

Manufacturing facilities often face high energy costs due to a lack of real-time insights. Even when operating under similar conditions, machines consume electricity inconsistently, making it difficult to detect inefficiencies and control expenses.

Unexpected Costs

Tracking machine usage and maintenance needs is challenging, leading to unexpected downtime and rising costs.

Solution

power consumption

CT10X

LoRaWAN® Gateway

IoT Cloud Platform

With the help of Heliotics, the customer successfully deployed a non-intrusive power monitoring solution featuring Milesight CT10x Smart Current Transformers to provide real-time energy insights without disrupting operations. This IoT-based system enables remote monitoring, predictive maintenance and data-driven decision-making, helping to optimize efficiency and reduce costs. Around 30 devices were deployed across 10 machines and the CT10x was deployed on almost every machine in the factory.

Milesight CT10x Smart Current Transformer is an ideal candidate in this project. Installing the current transformer is a breeze as you don't need to care about the current direction. Its split-core design enables easy installation without interrupting the circuit. Using magnetic induction, it captures the magnetic field generated by the current and converts it into an electrical output proportional to the measured current. For example, you can input the nominal voltage, current, and power factor to come out with the general power consumption. It can offer automatic calculation of cumulative amps-hour values once per second, so the detection frequency is one second. And it can be pre-charged and configured using the USB Type C, enabling a swift and hassle-free setup with the LoRaWAN® gateway. For your convenience, the configuration can be done via USB other than NFC.

Data collected from Smart Current Transformer installed in multiple machines across automotive facilities is presented in centralized platform, showcasing real-time inefficiency detection from continuous monitoring of energy usage. The Heliotics CORE IoT Monitoring Platform provides real-time electricity insights to help businesses reduce costs and optimize energy usage. Milesight smart sensors track power consumption, detecting inefficiencies and anomalies early. All data is displayed in an intuitive dashboard, offering a clear overview of energy usage and cost distribution. The system operates wirelessly via LoRaWAN®, ensuring seamless data transmission. With a non-invasive, cable-free installation, it integrates smoothly into operations, enabling proactive decision-making and lower maintenance costs.

Results

Decreased in Energy Costs

This solution has significantly improved energy efficiency while reducing costs through real-time monitoring and predictive maintenance. A 21% reduction in energy costs, saving 50,000€ per year across 10 machines, enhances sustainability and lowers expenses. Additionally, maintenance costs have decreased by 11%, extending machine lifespan. The system ensures operational optimization, improving performance and reducing inefficiencies.

Reduced Manual Costs and
Improved Maintenance Efficiency

After installing an electricity monitoring device on a machine or distribution box, a technician would typically need to perform a revision report. But in this project, the revision report was not required thanks to the non-intrusive deployment and automated monitoring of the CT10x.

Centralized Management for Data
-driven Decision Making

LoRaWAN® connectivity solutions are designed for durability, the deployment of LoRaWAN® solutions allows for rapid network expansion without sacrificing service quality while also reducing operating costs.

Why Choose Milesight

The CT10x was selected for its non-invasive design, eliminating the need for external power cables while being self-powered through its current transformer. Its compact design ensures seamless installation even in challenging and hard-to-reach environments.

Furthermore, the CT10x offers exceptional accuracy, capable of detecting even the smallest fluctuations in consumption. Unlike other devices that require a technician to perform routine revision reports after installation, the CT10x eliminates this need, which is a significant benefit for our customers.

Additionally, its straightforward deployment and configuration via Milesight Toolbox platform streamlines the process, delivering efficient, reliable and low maintenance monitoring solutions.

Milesight Partner

About Heliotics

Heliotics provides comprehensive software solutions for production and industry monitoring, utilizing IoT technologies such as LoRaWAN® and NB-IoT. The Heliotics CORE NO-CODE platform offers a highly customizable and scalable solution, integrating a range of smart sensors that empower manufacturers to efficiently monitor and manage their production operations.

Heliotics focuses on delivering seamless connectivity and real-time data analytics. Our platform streamlines monitoring, control and data integration while providing features such as predictive maintenance, downtime reduction, real-time alerts and advanced analytics for deeper insights.

With over a decade of experience across a wide range of industries, including automotive, logistics and machinery, we offer scalable, user-friendly solutions that help organizations optimize their processes, improve efficiency and make data-driven decisions.

Non-intrusive Power Monitoring Solution: About21% Reduction in Power Consumption for 10Machines with an Annual Saving of Around50,000 Euros

Background

Challenges

Solution

Results

Why Choose Milesight

Milesight Partner

About Heliotics

Non-intrusive Power Monitoring Solution: About
21% Reduction in Power Consumption for 10
Machines with an Annual Saving of Around
50,000 Euros