Reducing Costs Through Smarter Utilities Management

Industrial organisations globally are facing unprecedented pressures due to soaring electricity and fuel prices, with some regions witnessing increases of 200-300% compared to previous years. These expenses threaten the viability of many businesses, particularly in energy-intensive sectors. Compounding this issue is the rising cost and volatility of raw materials, compounded by water stress from changing weather patterns and ineffective water management practices. In this climate, companies are under increasing pressure from investors, consumers, and legislators to adopt more sustainable practices.

To address these mounting challenges, industrial companies must rethink their value chains and enhance resource efficiency and effectiveness. Many have set ambitious sustainability targets with deadlines between 2025 and 2050, necessitating tangible progress year over year. However, two primary obstacles stand in the way: accessing high-quality data relevant to sustainability goals and understanding how to act on that data effectively.

One powerful solution to these challenges comes from utilities optimisation software, such as Proficy from GE Vernova. This technology integrates existing HMI, SCADA, MES, and historian systems with modern dashboards and industrial analytics. It enables companies to monitor and optimise resource consumption in real time. By putting the right data in the hands of decision makers and enhancing it with insights powered by artificial intelligence and machine learning, organisations can manage their resource usage more effectively at the point of consumption.

Implementing utilities optimisation solutions can lead to significant benefits. Companies typically achieve energy savings of 10% or more in the first year, alongside obtaining contextualised data vital for advancing sustainability metrics, such as Scope 1 and Scope 2 carbon footprints. The software allows for the simultaneous management of operational emissions and other key performance indicators like cost, quality, and throughput.

Empowering companies involves three critical elements:

1. Access to Real-Time Data

Proficy connects to historical production data, facilitating real-time monitoring and correlation with key operating conditions. This empowers organisations to respond promptly to inefficiencies and adjust operations dynamically.

2. Actionable Insights

The advanced analytics capabilities detect previously unnoticed patterns in resource usage, enabling companies to make informed decisions that optimise performance and lower costs.

3. Continuous Improvement

Regularly assessing data and performance metrics cultivates a culture of accountability and improvement, helping organisations stay on track with sustainability targets while enhancing operational efficiency.

For example, a large automotive Tier 1 OEM achieved 18% energy savings in heating processes after integrating Proficy with its existing SCADA systems.

Similarly, a leading glass container manufacturer reduced furnace emissions by 80% while improving quality and efficiency, resulting in 25% reductions in defects and downtime. Additionally, a national library reduced energy consumption by 20-25% over four years through effective resource management across multiple sites.

Utilities optimisation software helps industrial companies overcome critical sustainability challenges while enhancing operational performance. By turning complex operational data into clear, real-time, and actionable insights and committing to continuous improvement, organisations can achieve notable energy savings and drive meaningful progress toward their sustainability goals.