+50
daily monitored buildings
Denso: industrial energy efficency in the automotive sector
Use Case
Energy efficiency
The industrial energy landscape is undergoing a significant metamorphosis, a transformation that goes far beyond the simple relationship between production and consumption.
We are witnessing the extraordinary evolution of the role of industries in the energy transition and a series of key factors, including the growing adoption of strategic agreements with network operators through Power Purchase Agreements (PPA) and Energy Performance Contracts (EPC), as well as a careful modulation of each industry's potential in terms of energy efficiency, energy production, self-consumption, and flexibility with the grid, in relation to the model of microgrids and UVAMs.
In this scenario, which requires a high level of digitalization increasingly in line with the paradigms of Industry 4.0, Apio has brought all its know-how and advanced technology to meet Denso's needs with a platform designed by ISO 50001 regulations that allows it to continue to be a leader in the automotive industry sector in the new energy scenario.
Project's KPI
+100 GWh
daily energy managed
+20%
saving by predictive mantainance
Sustainable goals achieved with the project
Implementation of an Integrated Solution for the Optimization of Energy Information Flow and Economic Analysis of Production.
In the context of efforts aimed at optimizing energy management and integration with production processes, the engineering team at Denso's San Salvo (Chieti) facilities emphasized the essentiality of meticulous monitoring of energy flows and operational collaboration with existing corporate management systems, such as Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES). This initiative aims to consolidate an integrated information ecosystem capable of effectively interacting with the organization's IT infrastructures, preparing the company for increasingly intense interaction with the opportunities offered by the energy market.
In line with the philosophy of agnostic interoperability promoted by Apio, the implementation of advanced sensors for measuring energy consumption has been initiated, exploiting wireless data transmission technologies such as Wi-Fi and LoRaWAN. This approach has made it possible to overcome the limitations of wired infrastructures, promoting flexible and minimally invasive installation.
To enhance the analysis of the economic impact of energy consumption on production, a next-generation platform has been developed. This solution allows for detailed monitoring of the main energy vectors (electricity, gas, water) used in the plants. Thanks to this system, Denso's technical staff can now accurately calculate the energy cost associated with the production of each component, integrating this information with existing corporate IT resources (ERP, MES).
What we have done was to analyze Denso's request and apply the majority of our frameworks to a solution that met every need, allowing us to create a ready-to-use platform within just 8 months.
How to gain an in-depth look at energy flows
Generally, the platform allows for monitoring the overall consumption of electric, thermal, and water energy vectors providing a global analysis of flows. This overview enables an understanding of the energy balance of the entire industrial complex, providing a solid foundation for identifying possible inefficiencies and implementing energy-saving strategies. This level of analysis is crucial for Denso as it allows for compliance with current regulations and the achievement of energy certifications such as ISO50001.
Specifically, it enables the analysis of consumption divided by macro-category such as main services, auxiliary services, and general services. This segmentation allows for a more precise evaluation of the energy weight of the different sectors of the industrial complex, such as main, auxiliary, and general services. This level of detail is indispensable for Denso for the implementation of targeted energy-saving actions, allowing efforts to be focused on the most significant areas of consumption.
Going even further into detail, the platform allows for monitoring the consumption detail divided by end use (lighting systems, plants, machinery, etc.). It takes the analysis to an even more detailed level that identifies the specific operational areas that require a greater amount of energy. This level of analysis is fundamental for the optimization of industrial operations, allowing for a reduction in energy consumption without compromising productivity.
Moreover, the platform ensures Denso can achieve a detailed analysis of energy consumption at the level of individual or group usage. This specific division allows for monitoring the energy consumption of each single element or group of elements, such as refrigerator groups, lights, or electrical equipment. This level of analysis is essential for optimal energy management, allowing for the identification and correction of possible inefficiencies at the individual user level.
This solution proves to be fundamental not only for Denso professionals directly involved in production operations and energy efficiency management but also for various company departments, affecting daily operations, and strategic decisions in key areas such as Facilities, Business, and Marketing.
These latter, thanks to the acquired data, can exercise a more informed and secure control over processes, consumption, and production costs, promoting a holistic management of energy resources in line with sustainability goals and reduction of operational costs.