From fragmented data to smarter energy management: How TT PSC’s Energy Advisor connected 10 manufacturing plants

About the customer

TT PSC partnered with a global food manufacturing company, employing over 100,000 people worldwide. One of its European production sites was selected as a pilot location for a new energy monitoring program, with plans for rollout across the FMCG sector in the EMEA region. 

Project Background

The project initially started as a pilot implementation at a single production site. Following its successful deployment, the solution was rolled out across the remaining sites, extending the same approach across the organization.

The client aimed to identify energy losses, standardize monitoring processes, and improve the accuracy and comparability of key performance indicators across the sites. The initiative was designed to enhance cost transparency and support more predictable, data-driven operational decisions across the organization.

By bringing together data from all 10 sites, the solution created a regional view of energy performance, with each plant representing a piece of the larger puzzle. When combined, these individual pieces provided a complete picture of the region, enabling the client to compare facilities, benchmark performance, identify gaps, and uncover opportunities for improvement across the network.

Business challenges

• Fragmented monitoring tools, limited visibility into energy losses, and inconsistent KPI calculations, leading to inaccurate cost reporting and poor comparability across periods.
• Evolving requirements and the involvement of multiple stakeholders, requiring strong governance, clear specifications, and continuous alignment between plant and management teams.
• Lack of a standardized, scalable monitoring environment aligned with corporate standards and compliance requirements for a global rollout.

Our solution

The Energy Advisor is a solution designed to help manufacturing companies optimize energy consumption and improve operational efficiency. It collects and integrates data from machines, production lines, and utilities, providing a comprehensive view of energy usage, costs, and operational performance. By combining real-time analytics with detailed energy insights, the solution helps identify energy losses, prioritize optimization opportunities, and assess where energy-related investments can deliver the greatest value. Its key advantages include cross-vendor integration, a modular and scalable architecture, and the ability to connect energy data with production context. The solution can also integrate with existing industrial infrastructure and adapt to different IoT platforms depending on client requirements.

Solution:

• A unified data environment integrating production systems and utility consumption data into a centralized platform.
• Standardized KPI calculation methodologies ensuring consistency across sites, production lines, and technologies.
• Role-based dashboards providing visibility for both plant teams and management.
• Automated reporting eliminating manual data preparation, reducing reporting delays, and improving data accuracy.

The solution enables transparent cost control, accurate performance benchmarking, and faster decision-making. By standardizing monitoring methodology and improving cross-level collaboration, it supports efficient rollout to additional plants and strengthens governance, compliance, and long-term sustainability initiatives.

Main results and advantages

The implementation of Energy Advisor delivered measurable energy savings within the first year of use, ranging from several to several dozen percent across individual facilities. The results varied depending on local conditions, including energy costs and tariffs, renewable energy availability, and production technologies. Overall, the solution enabled each facility to identify and pursue energy-saving opportunities based on its specific operational and environmental conditions.