Energy monitoring software for manufacturing: see consumption where it occurs

SYMESTIC's energy monitoring software shows energy consumption per machine live and in relation to production, down to the energy cost per part, and you see which machine consumes energy at idle.

Energy meter and busbar in the control cabinet, the data source for energy monitoring software

The power bill tells you how much. Not what for.

One meter for the whole plant shows the total. Which machine consumes at idle, when the peaks occur and what a part costs in energy remains unknown.

North plant · Energy consumption yesterday · Example

18,400 kWhIdle visible

Press 15,200

Hardening furnace3,900

Injection molding 24,100

Compressed air3,600

Other1,600

Plant meterone total, no assignment

ProductionIdle

MachineConsumptionof which idleper part

Press 15,200 kWh22%0.42 kWh

Hardening furnace3,900 kWh31%1.10 kWh

Injection molding 24,100 kWh14%0.18 kWh

Compressed air3,600 kWh38%–

Other1,600 kWh––

How energy monitoring works

Capture.

Consumption values come as process values via OPC UA from the machine or from meters, connected via plug and play.

OPC UA

MachineMeter

Assign.

Every consumption value is tied to machine, time and part count. That makes idle consumption visible and consumption per part calculable.

612 kWh

Press 1

1,460

Parts

0.42

kWh per part

Act.

Peak loads and deviations appear live.

Peak load 07:15 · above limit

Energy report

What is included

Automatically detect energy consumption at idle

Energy consumption per machine in real time

Detect peak loads

Energy costs per part

Energy reports

Limits and notification

Passed on via REST API

What our customers achieve

From pilot to group solution, implemented by your own team.

−10%Downtime

+7%Output

4 plants

productive in 6 months

Replacement of an existing MES, fully connected in 6 months.

8Countries

3Continents

510

segments across 12 plants

First machines in operation after just one day and KPIs analyzed worldwide.

>95%less CAPEX

20+Sites connected

>90%

shorter project time for machine connection

GMP-regulated pharmaceutical packaging: from the pilot line to all lines at the site, without touching the PLC.

0PLC interventions

3 weeks

until all lines are live

After a joint workshop, the key users run SYMESTIC on their own; Customer Success only supports on occasion.

Day 1Real-time data at the line

100%Real-time transparency

100%

Self-sufficiency

Works well with

Use case Reduce scrap Check process values against limits. View Industry Metalworking Energy, ERP and legacy machines. View Role Executive management One version of the truth across all plants. View Platform The MES platform All use cases on one platform. View

Frequently asked questions

What is energy monitoring in manufacturing?

The continuous capture of energy consumption per machine or area, time-resolved and in relation to production. It shows where energy is lost at idle and when peak loads occur.

How is energy consumption captured?

As a process value via OPC UA, straight from the machine or from a meter, connected plug and play.

Can SYMESTIC see when a machine consumes energy at idle?

Yes. Every consumption value is tied to machine, time and part count. That shows you which machine draws power even though it is not producing.

Can the energy cost per part be calculated?

Yes. Because consumption is tied to part count, you see consumption per part and thus the energy cost per part.

Will I be notified of peak loads?

Yes. You set limits; when one is exceeded, a notification is sent.

See your consumption per machine.

30 minutes, free of charge.

Christian Fieg

Head of Sales · SYMESTIC

Over 25 years in the manufacturing industry · Six Sigma Black Belt · global MES rollouts in automotive

“I will also tell you in the conversation if SYMESTIC does not fit your production. That saves us both time.”

What you take away from the call

A first assessment of what will measurably improve in your plant: OEE, downtime, reporting effort

The answer to how your machines and your ERP would actually be connected (via OPC UA, digital signals or the REST API)

A realistic pilot scope: one line, one use case, a clear time frame

Book a demo with Christian

30 minutes · Microsoft Teams · no obligation

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No preparation needed. All that helps is: which machines do you run, and which ERP do you use?

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Customers in 15 countries ISO 9001 “SYMESTIC gives us end-to-end real-time transparency that we did not have in this form before.” Thorsten Manns, Technical Director, Schmiedetechnik Plettenberg