Plant energy monitoring and efficient management

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Summary of the entity:

Idea75 provides innovative solutions for process optimization and energy efficiency of industrial plants following the new guidelines of Industry 4.0 and ISO50001. The company has gained skills and experience in design and implementation of system automation, monitoring and supervision of production lines and automatic control systems. Idea75 has installed a smart supervisor for the energy efficiency of the flour mills for the largest European producers of semolina flour. The smart supervisor was installed in 6 production plants monitoring over 3000 devices.

Summary of the challenge:

Description:

Industrial companies approaching digital transformation have to go through a complex journey which requires specific knowledge and great investment. The capabilities to analyze and correlate data are scarce and require long and costly manual activities. It is very frequent to proceed by relying on the experience of operators with considerable problems in managing high production rates and satisfying market demand.

Technical solutions providers are developing and offering in the last years new IT tools which aim to facilitate the digital transformation processes and to obtain valuable results. But this field of research and the related market sector are far from being settled offering great opportunities for new players and solutions to emerge.

This challenge is about plant monitoring system with CPS and IoT technologies and aims to create an easy-to setup tool for plant energy monitoring and efficient management in term of: energy data visualization within a plant spatial geometry of each monitored asset, digital twin ready solutions to be powered with different data sources and to be upgrade with future control features, advanced data analytics for decision support, innovative and integrated management interface for production, maintenance and general operations. The collection of plant production and energy data give chance to have a complete monitoring of industrial operations as well as to exploit advanced analytical and AI-powered tools to conduct efficiency and optimization analysis which may lead to profitable business decisions.

The ultimate scope is not only to promote awareness of energy consumption but to unveil the benefit of digital transition with integrated, convergent and easy-to setup and to use solutions also for non-technical users and making them accessible to a vast audience of companies.

Technical solutions providers are developing and offering in the last years new IT tools which aim to facilitate the digital transformation processes and to obtain valuable results. But this field of research and the related market sector are far from being settled offering great opportunities for new players and solutions to emerge.

This challenge is about plant monitoring system with CPS and IoT technologies and aims to create an easy-to setup tool for plant energy monitoring and efficient management in term of: energy data visualization within a plant spatial geometry of each monitored asset, digital twin ready solutions to be powered with different data sources and to be upgrade with future control features, advanced data analytics for decision support, innovative and integrated management interface for production, maintenance and general operations. The collection of plant production and energy data give chance to have a complete monitoring of industrial operations as well as to exploit advanced analytical and AI-powered tools to conduct efficiency and optimization analysis which may lead to profitable business decisions. The characteristics and availability of current processing technologies make them suitable to solve the digital transition challenge of various size enterprises: data can be easily collected and visualized with synthesis methodologies and digital twins solutions, big data analysis give chance to aggregate and correlate data and to extract business critical information, AI algorithms can detect anomalies, predict future values and estimate complex KPIs.
The ultimate scope is not only to promote awareness of energy consumption but to unveil the benefit of digital transition with integrated, convergent and easy-to setup and to use solutions also for non-technical users and making them accessible to a vast audience of companies.

Data:

• Active Power
• Energy
• Average Current
• Average Voltage

Expected outcomes:

• Reduction of production waste by 20% according to the ZDM paradigm;
• Reduction of the unsold product rate of 10% due to bad quality.