Energy data management system for manufacturing

Gain full visibility of your energy use in a single system. From the shop floor to the boardroom — and turn data into measurable savings.

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Why energy management is hard to ignore today?

If you run a factory, you know how fast energy costs eat into your margins. Prices change, regulations tighten, and sustainability targets keep growing.

Without proper energy management, it’s hard to tell where energy is really going — which lines or machines waste the most, and what can actually be improved.

A solid energy data management system gives you real numbers in real time, so you can act early — before small inefficiencies turn into real costs.

Challenges faced by plant decision-makers

From hidden energy losses to unreliable data, these challenges prevent manufacturers from achieving true efficiency.

No single source of truth

Energy data is scattered across many tools, making decisions slow and uncertain.

Blind spots in energy losses

Hidden inefficiencies go unnoticed until they start costing real money.

Limited real-time insight

When reports finally arrive, it’s already too late to react effectively.

Hard to prove compliance

Without clear records, meeting ISO 50001 and audit standards becomes risky.

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Energy Advisor - our tailor-made solution

Engineer inspecting high-voltage power infrastructure with a tablet, symbolizing industrial energy monitoring and optimization in manufacturing.

Energy Advisor helps manufacturing enterprises make sense of their energy data.It collects information from machines, production lines, and utilities, showing where and how energy is really used.

With it, you can see which areas generate the biggest losses, where investments will pay off fastest, and how to keep costs under control at any time.

It gives you facts you can rely on - useful not only for engineers on the shop floor, but for managers who make the financial decisions.

Energy management designed for your needs

Our Energy Management Software provides a comprehensive suite of tools to manage energy consumption and improve efficiency across electricity, gas, water, and production processes. It also supports sustainability energy monitoring, helping you track progress toward your environmental goals.

Thanks to our modular platform, you can integrate electricity, gas and water meters, production equipment, and even power-quality sensors – all within one unified system. It’s designed to work with minimal programming effort, ensuring a quick and seamless start.

The advantage of Energy Advisor over a standard EMS

Cross-vendor integration

Energy Advisor:
Connects and collects data across different manufacturers — one layer over

Standard EMS:
Usually tied to a single vendor; hard to scale and expensive to change.

Why it matters:
You see the full picture of energy use and stop paying for “invisible” waste hidden in other utilities.

Increase machine efficiency

Energy Advisor:
Supports multiple media types — electricity, gas, water, compressed air, steam, and more.

Standard EMS:
Often limited to electricity monitoring only.

Why it matters:
You see the full picture of energy use and stop paying for “invisible” waste hidden in other utilities.

Comprehensive analysis

Energy Advisor:
Combines process parameters, energy costs, and KPIs for deeper operational insights.

Standard EMS:
Focuses on live consumption data without context.

Why it matters:
You fix what truly impacts your margin — not just what looks good on a chart — using data-driven energy management solutions.

ISA-95 alignment

Energy Advisor:
Aligns media consumption with the ISA-95 production hierarchy for structured, scalable energy management.

Standard EMS:
Works without a unified hierarchy, leading to inconsistent reporting.

Why it matters:
You get clean, comparable data from the shop floor to management — a foundation for long-term energy efficiency solutions.

Multi-dimensional insights

Energy Advisor:
Combines process parameters, energy costs, and KPIs for deeper operational insights.

Standard EMS:
Focuses on live consumption data without context.

Why it matters:
You fix what truly impacts your margin — not just what looks good on a chart — using data-driven energy management solutions.

Measurable results you can expect from energy management

Reduce energy consumption by up to 30%

Spot inefficiencies early and prevent unnecessary energy losses across operations.

Cut operational and production costs

Lower utility spending and optimise resource use without disrupting production.

Improve efficiency and sustainability performance

Lower carbon emissions with data insights Energy data is scattered across many tools, making decisions slow and uncertain. Use verified data to track, control, and reduce your organisation’s carbon footprint.

Lower carbon emissions with data insights

Use verified data to track, control, and reduce your organisation’s carbon footprint.

Drive continuous improvement and smart decisions

Base every operational and investment choice on reliable, real-time energy data. Detect hidden losses caused by harmonics or unstable loads before they impact costs.

Gain visibility and control over power quality

Detect hidden losses caused by harmonics or unstable loads before they impact costs.

Case Study

See how a global food manufacturer cut energy costs and improved sustainability with Energy Advisor by TT PSC.

  • Automated data and real-time insights
  • Measurable cost and CO₂ reductions
  • Scalable solution for multi-site operations

Download the full case study to see the results.

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Recognised for excellence

Choose smart and simple energy management.

Innovation in Bussines 2022

Innovation in Bussines 2022

German Innovation Award

German Innovation Award

The Best of Industry 4.0

The Best of Industry 4.0

Watch the demo to explore how Energy Advisor visualises consumption, pinpoints inefficiencies, and supports smarter, data-driven decisions.


Why choose TT PSC

Deep manufacturing expertise

We understand the realities of the plant floor, so our OEE systems solve real production challenges, not just technical ones.

Risk-free Proof of Concept

Start small with a pilot project instead of a full-scale investment. A PoC minimizes risk, validates data integration, and shows quick wins before you scale Unified Namespace across the entire enterprise.

Global Presence, Local Support

With delivery centers across Europe and the UK, we offer the strength of an international organization with the agility of local, on-site support.

Flexible and Easy to Work With

Our streamlined structure allows for fast decision-making, simplified contracting, and minimal administrative burden — accelerating project start-up and execution.
They trust us:
Philip Morris International
Lufthansa Technik
Gentherm
Schaeffler
Oerlikon
SEG Automotive
ESAB
Haarslev
FCA
OCME
Solaris
Lacroix
Vestas

Feedback from our customers

Let’s talk about your energy goals

In 30 minutes, we’ll show you where your factory can save power, reduce costs, and improve overall performance.

Key system features

Real-Time energy management

  • Monitor and control energy consumption and the operation of heating, cooling, or other energy-intensive systems in real time within the ISA-95 production hierarchy and in correlation with manufacturing data.
  • Track key energy performance indicators (KPIs / EnPIs) to continuously improve efficiency and reduce costs.
  • Visualise and analyse consumption through interactive charts and trend graphs — identify the largest consumers, compare performance per product, production line, or order, and detect optimisation potential.

Monitor Energy Quality and Compliance

  • Gain a deeper understanding of production costs by analysing the energy and media component across different perspectives (line, department, product).

  • Evaluate and optimise your energy mix and production planning to ensure maximum utilisation and minimal waste.

  • Generate detailed cost breakdowns that link energy data directly to business outcomes.

Monitoring of Energy Media Parameters

  • Ensure compliance with contracted quality standards for all monitored media.

  • Detect and document deviations from contractual norms and automatically notify relevant stakeholders.

  • Visualise parameter changes over time and access historical reports for audits or technical reviews.

Alerts and Notifications

  • Monitor all key parameters — including quality indicators, measurements, and KPIs — in one system.

  • Receive automated alerts via SMS, email, or in-app notifications, configured for individual users or groups.

  • Use historical alert logs to speed up troubleshooting and prevent recurring issues.

Power Guardian – Contract Power Protection

  • Continuously monitor instantaneous electricity consumption (and other media if applicable) against the contracted capacity.

  • Predict total consumption for the current billing period using advanced forecasting algorithms.

  • Receive early alerts when predicted usage may exceed contracted power limits — allowing timely preventive action. Forecasting Future Energy Costs

Forecasting future costs

  • Calculate future energy costs based on historical data and projected energy prices.

  • Simulate and compare multiple scenarios with varying tariffs, consumption levels, and media mixes.

  • Use these insights to plan production and purchasing strategies that minimise long-term energy expenses.

Managing Energy Sustainably to Meet ESG Goals

  • Measure and report the carbon footprint of your production sites and operations in line with UK and EU standards.

  • Monitor the progress of Net Zero and ESG initiatives as part of your wider corporate sustainability strategy.

  • Understand and document how individual machines, production lines, or products contribute to your total CO₂ emissions, helping you set realistic targets and demonstrate compliance.\

Custom Features

  • Add new functionalities and analytical tools tailored to your company’s specific business and operational needs.

  • Manage energy your way — the system adapts to your organisation, not the other way around.

  • Our specialised engineering and analytics teams will help you choose the right modules and guide further development directions.

ISO 50001 certification support

Our Energy Management System is custom-built for your organisation — flexible, scalable, and aligned with your operational needs.

While it is not pre-certified, TT PSC collaborates with accredited certification bodies to help you achieve full ISO 50001 compliance after implementation.

Our experts and partners support you at every stage:

  • Define Energy Performance Indicators (EnPIs)
  • Map and document energy flows
  • Ensure regulatory compliance
  • Map and document energy flows
  • Map and document energy flows

This approach gives you the best of both worlds — a tailored, data-driven system built around your operations, and the confidence to meet ISO 50001 requirements with full traceability and expert support.

Our process

A structured, step-by-step path toward comprehensive energy management — helping you lower costs, enhance efficiency, and achieve long-term sustainability.

1

Initial Assessment

We begin by analysing your current energy performance to identify areas with the highest optimisation potential.

2

Data Collection & Connectivity

Our system integrates seamlessly with existing meters and sensors to enable real-time data flow.

3

System Design & Integration

Using a modular design, we connect SCADA, MES, and IoT infrastructure to create a single, unified platform.

4

Pilot & Validation

A targeted pilot validates system performance and demonstrates substantial savings before a full rollout.

This stage sets the foundation for digital transformation and informed decisions based on valuable insights.

Technical advantages of Energy Advisor

Seamless integration

Easily connects with ERP, MES, SCADA, PLCs, and IoT systems — no need to replace existing infrastructure.

Vendor-agnostic architecture

Works with any hardware or software — no vendor lock-in.

Modular and scalable design

Add new features or modules as your needs grow, without rebuilding the entire system.

Real-time analytics

Processes and visualises high-frequency energy data instantly, enabling quick and informed operational decisions.

Secure and compliant

Built with enterprise-grade cybersecurity and GDPR compliance to protect your critical industrial data.

ISA-95 data model

Structures energy data according to the ISA-95 hierarchy, ensuring consistency and comparability across all production levels.

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Success Stories

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Frequently Asked Questions

SCADA supervises and controls industrial processes in real time, while an EMS focuses on analysing and optimising energy use across systems to reduce costs, increase efficiency, and support sustainability goals.