Following our breakdown of the core principles of energy monitoring, we now take a closer look at a real-world success story, showcasing energy monitoring in action.

We sat down with Bart Dieusaert, Analytics Manager for Operations at Etex, to discuss how Sensr helped Etex implement Energy Monitoring Systems (EMS), optimize energy usage, and drive progress toward its sustainability goals.

In the world of building materials, Etex stands as a global innovator in lightweight construction solutions. While the company offers a diverse range of products, including plasterboards, fibre cement boards, and insulation materials, one major challenge they face is the high energy consumption required for the production of plasterboards.

To address this challenge, Etex decided to implement energy monitoring in its plasterboard plants, enabling them to track energy consumption across electricity, gas, steam, and other fuel sources. This data is then combined with quality and process data to generate actionable insights. Together with Sensr, they embarked on a journey to enhance energy efficiency.

Etex’s energy optimization journey began at its pilot plant in Italy, a factory with a single production line and significant energy demands, making it an ideal testing ground. The process started with the installation of sensors at critical points in production to track energy variables such as electricity, gas, and water usage. “We started by installing sensors on our plasterboard production lines,” explained Bart. “These sensors monitored the energy consumption of individual machines and the overall production line. The data was then fed into Etex’s Data Platform, providing real-time insights into our energy usage.” This real-time monitoring allowed Etex to visualize energy consumption patterns, detect inefficiencies, and make data-driven decisions to optimize energy use. For example, by measuring water loss during the drying stage, they could determine whether boards were too wet or too dry, enabling adjustments that minimized energy waste.

With the EMS in place, Etex was able to transform raw energy data into actionable insights. The system generated three types of reports:

1. Real-time reports: These reports provide operators with live visualizations of energy consumption on factory floor screens. Data is collected every ten minutes and displayed next to the machines, allowing operators to take immediate action if key performance indicators (KPIs) deviate from the norm. The real-time data is stored for up to eight hours, offering a short-term view that supports quick decision-making and adjustments to optimize processes and reduce energy consumption.
2. Process parameter reports: Designed for process engineers, these reports provide comprehensive historical data, integrating various process parameters such as production square meters and water loss during the drying process. Engineers can use this data to identify long-term optimization opportunities and refine production processes. For example, by analyzing temperature limits in the mixing stage, they can set upper and lower thresholds to optimize energy use while maintaining product quality, preventing energy waste and ensuring product standards.
3. Daily reports: These reports consolidate daily energy data, providing plant managers with an overview of consumption patterns. They play a crucial role in strategic decision-making, helping managers identify areas for improvement and determine which production lines to investigate for potential energy savings.

Building on the success of the pilot project in Italy, Etex expanded the EMS to two additional plants in Latin America (Chile and Brazil) and aims to implement it across multiple plants, prioritizing those with the highest energy consumption for maximum impact.

Bart stated, “Working with Sensr has led to significant reductions in energy waste and cost savings for Etex. We are excited to extend these benefits to more plants worldwide.”

The success of this project has been fueled by the combined efforts of Sensr and Etex. Sensr designed the IT architecture, managed data engineering, and continues to provide hands-on support during the rollout to new locations.

As Etex continues expanding its EMS across more factories worldwide, several challenges emerge. A key hurdle is standardizing data input and maintaining data quality across diverse manufacturing sites, each with unique configurations and local practices. Integrating advanced data analytics requires a robust data governance framework, which can be difficult to implement consistently across multiple locations.

Additionally, ongoing training and support for plant operators and process engineers are essential to fully harness the capabilities of energy monitoring. Ensuring seamless interaction between onshore and offshore teams, while maintaining flexibility and clear communication, will also be critical to the project’s continued success.

Despite these challenges, Etex’s expansion efforts continue to be driven by its commitment to sustainability and energy efficiency.

The combined efforts of Etex and Sensr highlights the transformative power of energy monitoring in the industrial sector. By leveraging advanced technologies and data analytics, Etex has not only reduced its energy consumption but also made meaningful progress toward its sustainability goals. As Etex continues rolling out the EMS across its global operations, Sensr remains a dedicated ally, providing ongoing support and expertise.