Case study: how a 12-plant manufacturer cut energy spend 27%

The company ran twelve manufacturing plants across four states. Each plant reported energy data differently — some monthly, some quarterly, some not at all. No one in the head office could answer a simple question: which plant is our least efficient, and why?

The starting point

• 12 plants, 4 states, zero unified visibility.
• Energy reporting stitched together from spreadsheets, weeks out of date.
• Annual energy spend of ₹25 crore — and no idea where the waste was.

What changed

Within six weeks, every plant was reporting into one normalized data layer. The intelligence engine immediately flagged three high-impact issues: overnight HVAC at the Pune plant, a fleet of aging chillers in Bengaluru, and avoidable peak-hour load at two sites.

“For the first time we could rank our plants by efficiency. The worst one was not the one we assumed.”

— Group Head of Operations

The result

Twelve months later, energy spend was down 27% — ₹6.8 crore in annual savings — with carbon emissions down a comparable margin. The single largest contributor was not new equipment. It was finally knowing what the existing equipment was doing.