Problem
Businesses face a unique challenge when it comes to power consumption billing. Unlike private customers, whose bills are calculated solely based on kWh usage, business customers are billed for both their kWh usage and the highest load peak recorded over the past year. For energy network operators, maintaining stable power delivery is critical. However, load peaks from high-consumption businesses present significant challenges, prompting additional charges for these peaks.
Typically, load peaks are measured over a year-long timeframe. A single instance of a load peak can lead to substantial costs for businesses, sometimes reaching tens of thousands of euros in extra charges annually. This issue becomes particularly severe for energy-intensive companies, where even a brief surge in consumption can have far-reaching financial consequences.
For instance, a customer in the plastic production industry experienced this firsthand. One morning, as employees simultaneously started their machines, a significant load peak was created. This single event resulted in a considerable financial impact for the company. The need for a solution to mitigate such occurrences became evident, introducing the concept of Peak Shaving—a method to eliminate or reduce these load peaks from a company’s power profile. Such peaks frequently arise from the simultaneous startup of heavy machinery, which generates high inrush currents.
Solution
To address this recurring issue, a tailored solution was implemented using the achtBytes IoT Solution in partnership with the customer. The system relied on IO-Link power consumption sensors integrated with the analytics module of the IoT platform. This setup provided the company with the ability to monitor the individual power consumption of each machine in real time. By aggregating and analyzing this data, the combined power consumption of all machines could be assessed every second.
To enhance usability and prevent load peaks during machine startups, IO-Link 3-color segment lamps were installed beside each machine. These lamps served as visual indicators for machine operators:
- Green: Safe to start the machine.
- Yellow: Caution is advised.
- Red: Do not start the machine due to high current load.
This proactive system empowered employees to make informed decisions, effectively avoiding load peaks.
Result
The implementation of the achtBytes IoT Solution enabled the company to proactively prevent load peaks caused by simultaneous machine startups. This not only resulted in immediate cost savings but also eliminated the risk of financial penalties from unexpected load peaks.
Additionally, the retrofitting of existing hardware provided the customer with a clear view of individual machine consumption, all without incurring additional expenses. This newfound transparency in energy usage opened opportunities for better order planning and energy-saving strategies, adding long-term value to the business. Beyond mitigating costs, the solution encouraged smarter energy consumption practices, offering both financial and environmental benefits.