We are thrilled to announce the successful launch and implementation of a comprehensive Energy Monitoring System at INSEE Puttalam Cement Works (PCW), one of Sri Lanka’s leading cement manufacturers. This strategic project, spearheaded by INSEE’s Electrical team in close collaboration with UTECH IIoT Solutions, marks a significant leap forward in data-driven industrial energy management.
The Challenge: Gaining Granular Control in a Complex Environment
Modern cement plants are energy-intensive operations where even small efficiencies can translate into substantial cost savings and sustainability gains. The challenge lies in moving beyond high-level utility bills to achieve granular, real-time visibility across diverse and critical loads. INSEE PCW recognized the need for a centralized system to monitor consumption, identify anomalies, and empower data-backed decision-making.
The UTECH IIoT Solution: A Tailored Approach to Energy Intelligence
UTECH partnered with the INSEE team to design and deploy a fully customized Energy Monitoring System built on a robust IIoT (Industrial Internet of Things) foundation. The project was led by Mr. Thiloke Edirisinghe of INSEE, ensuring the solution met precise operational requirements.
Key implementation features include:
-
Extensive Network Integration: Seamless integration of over 65 energy meters across the plant, creating a unified data fabric for holistic energy tracking.
-
Real-Time Operational Awareness: Live dashboards provide instant insights into power consumption patterns, enabling proactive management.
-
Proactive Environmental Monitoring: The system delivers real-time alerts for temperature and humidity in critical VFD (Variable Frequency Drive) rooms, helping prevent equipment downtime and protect valuable assets.
-
Customized Reporting Engine: Automated generation of daily and monthly energy reports, tailored specifically to INSEE’s KPIs and management needs, eliminating manual data compilation.
-
User-Centric Design: All visualizations, dashboards, and alert mechanisms were fully customized to align with the plant’s workflows and operational priorities.
Official Launch & Strategic Endorsement
The system was officially launched in a ceremony graced by the presence of Mr. Thusith Gunawarnasuriya, Chief Operating Officer of INSEE Cement. His participation underscores the strategic importance of this digital transformation initiative in driving efficiency, sustainability, and operational resilience.
A Testament to Collaborative Success
“This project exemplifies how technology partnership can drive tangible industrial value,” said a spokesperson from UTECH IIoT Solutions. “The close collaboration with Mr. Edirisinghe and the skilled INSEE Electrical team was fundamental. Their deep operational knowledge, combined with our IIoT expertise, allowed us to deliver a system that is not just a tool, but a strategic asset for INSEE PCW.”
The Impact: From Data to Action
With this system now active, INSEE Puttalam Cement Works can:
-
Pinpoint inefficiencies and optimize energy use across production lines.
-
Reduce operational risks through predictive environmental alerts.
-
Support sustainability goals with accurate, auditable consumption data.
-
Make informed decisions backed by reliable, real-time information.
