Energy-intensive production facilities
Factories with melting, kiln, drying, pressing and cooling processes. In these plants energy is one of the decisive items in product cost, and it cannot be managed until it is measured.
CUSTOM SOFTWARE · ENERGY MANAGEMENT
Energy Management and Mandatory Reporting: From Meter to Product
We build a system that collects meter and field data and allocates energy to lines, machines and products. The basis for your annual declaration is ready, and a product's true energy cost stops being an estimate.
In most factories, energy is a cost item managed through a single bill. At month-end the total consumption and the amount are known; which department, which line and which product it came from is not. When the bill rises, the conversation usually turns to tariffs and contracts, because nobody knows where in the consumption to look. Yet for energy to be managed, it first has to be divided.
The second issue is energy's share of product cost. In processes such as melting, drying, baking, pressing, compressed air and cooling, energy is a cost item large enough to rival labour. It is usually allocated to product cost roughly, from the total. The result is that some products look more profitable than they really are and others look less profitable — and pricing decisions are taken on that false picture.
The system we build collects meter and field data, matches it with production records, and allocates consumption to lines, machines and products. Energy per unit produced becomes measurable; shifts, lines and periods can be compared. Idle consumption, loads that continue when nothing is being produced and abnormal spikes become visible. Once identified, most of the action needed is operating discipline, not investment.
This system also has an obligations side. Industrial facilities whose annual total consumption is one thousand tonnes of oil equivalent or more are required to employ an energy manager and file their annual consumption declaration every March. Once the system is in place, the data underpinning that declaration accumulates throughout the year; the reporting period stops being a scramble to compile. The same data infrastructure also feeds the embedded emissions calculation for manufacturers exporting to the European Union; building the two separately is needless duplication.
Who is it for?
Who is Energy Management and Mandatory Reporting a good fit for?
Industrial facilities with declaration obligations
Businesses whose annual consumption is one thousand tonnes of oil equivalent or more. These facilities are required to employ an energy manager and file an annual consumption declaration every March; the data underpinning the declaration must be kept in good order.
Manufacturers exporting to the European Union
Factories whose buyers ask for per-product emissions data. The emissions calculation is grounded in energy and fuel consumption; where the energy infrastructure is in place, the emissions side becomes a much shorter job.
Businesses with their own generation and storage
Facilities that have invested in, or are planning, solar plants, cogeneration or storage. The real return on such an investment can only be calculated when the consumption profile is known hour by hour.
What we build
What we deliver within Energy Management and Mandatory Reporting
Meter and field data collection
Data is collected from electricity, natural gas, steam, compressed air and water meters; existing meters' protocols are used, and additional measurement points are proposed where necessary. Data is stored at hourly or finer intervals; instead of a month-end total, you get a profile.
Line- and machine-level allocation
Consumption is allocated to departments, lines and machines according to measurement points. Not every machine needs its own meter; where inference from measured points and running times will do is decided together, and the assumptions are stated in writing.
Energy per unit produced
By matching with production records, energy consumption is calculated per product, batch or work order. How much the same product consumes on different shifts and different lines becomes comparable; in most plants, this comparison is the first concrete source of savings.
Idle consumption and anomaly detection
Consumption that continues with no production, weekend and between-shift loads, leaks and sudden spikes are detected. Compressed-air leaks and idling equipment are the classic findings of this analysis, and fixing them rarely requires investment.
Annual declaration preparation
The data the energy manager needs for the annual consumption report is compiled from records accumulated through the year. When the reporting period arrives there is no gathering to do; existing data is summarised and checked. The declaration is always filed by you.
Tracking efficiency projects
The before and after of each improvement are compared on the same measurement basis. Whether a project genuinely delivered savings is assessed net of changes in production volume; without that adjustment, every improvement looks successful.
Technologies
The technologies we work with
- Meter protocols and data acquisition
- Modbus and industrial communication
- Time-series data storage
- Production record matching
- Allocation and apportionment model
- Anomaly and idle-consumption analysis
- Dashboards and reporting
- Declaration preparation outputs
- Data feed into emissions calculation
Process
How we move from discovery to go-live
- 01
1. Measurement point inventory
Existing meters, their measurement capabilities and blind spots are mapped. What is measured today and what is estimated are separated. This step usually ends with a handful of proposed measurement points; rather than installing them all at once, we start with those that will yield the most information.
- 02
2. Setting up data collection
Data acquisition from the meters is set up and stored as time series. The goal at this stage is not analysis but reliable, uninterrupted data; how missing and faulty readings are handled is defined from the start.
- 03
3. Matching with production data
Consumption is matched with production records along the time axis. If the production side lacks sufficient breakdown, we discuss the minimum records needed. Allocation assumptions are put in writing; hiding an assumption destroys the credibility of the result.
- 04
4. Analysis and first findings
Idle consumption, line and shift comparisons and consumption per unit produced are reported. Findings are split into those requiring investment and those that do not; the second group is usually acted on first.
- 05
5. Handover of the declaration and monitoring routine
The outputs needed for the annual declaration are prepared and checked together with your energy manager. Who receives the regular monitoring reports, and how often, is agreed, and the system is handed over to your team.
Frequently asked questions
Common questions about Energy Management and Mandatory Reporting
Do we have to fit a meter to every machine?
No, and it is usually not recommended. Main lines and the biggest consumers are measured first; a significant share of the rest can be allocated by inference from running times and measured points. Where true measurement is needed is decided as findings emerge. Metering every point from day one rarely repays the money spent in most plants.
Does your system file the declaration?
No. You file the declaration through your energy manager; the system's job is to keep the underlying data accurate and uninterrupted throughout the year and to put it in front of you, compiled, when the time comes. Where direct transfer to an official interface is in question, we examine whether it is possible at the start of the project and say so plainly.
Do you also provide energy efficiency consultancy?
Energy audits and engineering consultancy are a separate discipline, and we do not claim to do them. Our job is to build the measurement infrastructure that decisions will rest on. If you work with an audit firm, this infrastructure makes their work easier too; an audit done on measured data yields different results from one done on assumptions.
Can it be used for emissions reporting too?
Yes — and that is one of the strongest reasons to build the infrastructure. The embedded emissions calculation is grounded in allocating energy and fuel consumption to products; once the energy side is in place, the emissions side largely uses the same data. This topic is covered in detail on a separate page.
Can data be read from our old meters?
In most cases, yes; the meters' communication support and the existing infrastructure are examined during discovery. For meters with no communications, either a reading module is added or that point is allocated by inference. Which route to take is decided by looking at that point's weight in the total.
What do we end up with?
An uninterrupted energy data infrastructure; consumption allocation by line, machine and product; an energy-per-unit indicator; idle-consumption and anomaly reports; compiled outputs feeding the annual declaration; and before-and-after comparisons of efficiency projects. Everything, including source code and the collected data, is one hundred per cent yours.
Contact
Let us talk about your Energy Management and Mandatory Reporting project
In a 30-minute discovery call we listen to what you need and tell you honestly whether custom development or an off-the-shelf product is the better answer.
Related
Related pages and guides
CBAM Emissions Reporting IoT and Embedded Systems Production Tracking and MES Environmental and Waste Compliance Management Let's Talk About Your Measurement Points After delivery: maintenance, support and capacity subscription
Custom CRM Software
Off-the-shelf CRM packages do not recognise the real sales flow of industry and export. We develop a custom CRM that talks to your ERP, modelling the long sales cycle, the sample-proforma-order chain, dealer management and quotation tracking around your own process.
Details →Payments & Fintech Integration
We develop custom payment software that unites virtual POS, digital wallet, reconciliation and invoicing flows in a single secure system, built on iyzico, PayTR and bank POS infrastructures.
Details →Pricing and Quote Optimisation (CPQ)
We build a system that shows you the true cost at quotation stage: raw material, scrap, labour, energy, tooling, packaging, freight, customs and payment-term costs gathered per product; currency and payment-term scenarios; a price band set against your target margin; and the win rate of past quotations.
Details →E-Export Tax and Multi-Country Compliance Automation
For e-exporters selling direct to consumers in Europe, we build a system that tracks country-level obligations in one place: thresholds, the filing calendar, invoice formats, producer responsibility registrations, and the different liability regimes of marketplaces versus your own site.
Details →Digital Accessibility Audit and Compliance
We audit your website, e-commerce store and customer portal against accessibility criteria, rank the findings by priority and apply the fixes. The goal is not a badge; it is an interface that is genuinely usable.
Details →Data, BI & Reporting
Custom business intelligence and reporting solutions that bring the data scattered across spreadsheets and systems into a single decision screen. Clean data through ETL, real-time KPI dashboards, and reports segmented by role.
Details →