• • • ENERGY EFFICIENCY • • •


Optimising energy use in manufacturing and the role


of data visibility With ever-increasing energy costs and growing environmental concerns, manufacturers are under constant pressure to enhance their energy efficiency


By Sayan Ghosh, Director, Commercial Strategy, APAC, Belden D


ata from the Eurostat indicates that the industrial sector accounts for approximately 25.1 per cent of total EU


energy consumption, while the International Energy Agency reports a global figure of 37 per cent. Reducing this consumption not only offers cost savings but also contributes to environmental sustainability and energy price stability, potentially answering regulatory challenges and energy market instability. To achieve energy optimisation in a tangible


sense, manufacturers must move beyond irregular audits and focus on continuous collection of real-time data. This allows facilities to identify processes when energy is lost or used inefficiently, to adjust operations, and make informed decisions that lead to energy savings.


Monitoring of real-time consumption vs.


intermittent audits Traditional energy audits provide a backwards view of energy use, often missing transient inefficiencies and not capturing dynamic changes occurring in the energy flow. In contrast, real-time monitoring through sensors and smart metres offers continuous energy consumption metrics. This approach allows for immediate detection of anomalies that can be instantly corrected. Effective energy optimisation actively reduces


consumption and plans strategic energy procurement at reasonable prices by measuring what is happening in the plant, and then aligning with grid data as available. By analysing historical consumption data (augmented through the use of industrial AI) alongside production schedules and market conditions, organisations can negotiate viable energy contracts based on operational needs.


Evaluating long-term investments with data against


short-term ROIs Investments in energy-efficient technologies often require substantial upfront costs with longer payback periods. Comprehensive data analysis provides the evidence needed to justify these investments by projecting long-term savings and operational benefits. Moreover, continuous monitoring allows for the assessment of implemented solutions, ensuring they deliver the anticipated energy reductions and informing future investment decisions.


14 ELECTRICAL ENGINEERING • JULY/AUGUST 2025 electricalengineeringmagazine.co.uk


Data sources and integration A variety of data sources contribute to a comprehensive understanding of energy use: • Sensors and Smart Metres: Monitor real-time energy consumption across equipment and processes.


• SCADA Systems: Collect and analyse data from control systems, provide insights into operational efficiency.


• Building Management Systems: Track energy use in HVAC, lighting and other building systems.


• Energy Management Software: Offer centralised platforms for analysing and visualising energy data.


• Maintenance Management Systems: Predict maintenance needs, preventing energy waste due to equipment inefficiencies.


Integrating these data sources into a unified


platform facilitates the identification of energy-saving opportunities and supports informed decision-making.


Implementing data-driven


energy optimisation To effectively leverage data for energy optimisation, manufacturers should: 1. Conduct a Digital Maturity Assessment: Evaluate current data collection capabilities and identify gaps.


2. Deploy Appropriate Technologies: Install sensors, smart metres and software solutions tailored to specific operational needs.


3. Ensure Data Integration: Establish a centralised system that consolidates data from various sources for comprehensive analysis.


4. Train Personnel: Equip staff with the skills necessary to interpret data and implement energy-saving measures.


5. Monitor and Adjust: Continuously assess energy performance and refine strategies to achieve ongoing improvements.


Energy optimisation in action Belden’s latest collaboration with AWS is set to streamline the collection and contextualisation of operational data on the shop floor. With the integration of AWS IoT SiteWise Edge and CloudRail, manufacturers can make use of a plug-and-play approach to connect shop-floor assets, aggregate valuable OT data and transfer it seamlessly to the cloud for analysis. The integration supports local monitoring and


analytics, as well as cloud-based applications. Consequently, this translates to rapid deployment and centralised device management implementation that is easier and faster. For example, a European beverage manufacturer deployed Belden’s IIoT solution to connect over 130 devices in just four weeks, achieving a 10 per cent reduction in energy usage through automated reporting and real-time visibility. The secure, vendor-agnostic platform scales effortlessly, it supports legacy systems while providing the resilience and security required by the business. By taking on the data-centric approach,


manufacturing facilities can transition from reactive to proactive energy management. The benefits are manifold, from significant cost savings, through improved performance to reduced environmental impact. The bottom line is that manufacturers who fail to adapt will lose competitive edge and lag behind more innovative businesses.


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