Automotive: energy efficiency in a production plant
Challenge
A major manufacturer of automotive components needed to reduce energy consumption at its production plant without investing in new machinery. Industrial plants, hotels and shopping centres now run with energy consumption that grows faster than their ability to control it: boilers, compressors, HVAC and lighting operate on fixed logic that does not adapt to actual production, occupancy or footfall. The result is excess energy cost, avoidable emissions and growing pressure, both regulatory and commercial, to demonstrate sustainability to increasingly demanding clients and distributors.
Solution
We implemented an AI solution that analyses data from 30 analysers distributed across the plant in real time, detecting inefficient consumption patterns and optimising processes continuously.
QALEON deploys an AI-based energy management system that integrates data sources (meters, IoT sensors, SCADA, BMS and MES systems) with predictive models of consumption and demand, plus a real-time optimisation layer over critical equipment. Beyond operational efficiency, the solution calculates and reduces the carbon footprint associated with that consumption (Scope 1 and 2), produces reporting aligned with sustainability standards to make audits and regulatory compliance easier (CSRD, EU taxonomy), and provides environmental impact indicators by plant, line or product that strengthen the company's ESG position with investors, clients and regulators, all without compromising quality, comfort or operating capacity.
Results achieved
A 27% to 31% reduction in energy consumption within 12 months
A carbon footprint reduction of up to 38% within 18 months (Scope 1 and 2)
Full traceability of energy and environmental performance by plant, line or zone
A differentiated position with clients, investors and regulators who demand verifiable environmental responsibility
