Combining Asset and Energy Management: The key to achieving sustainability targets in European industries

A successful approach toward a green future for industrial companies requires a combination of advanced asset management, effective energy management systems (EMS), and some AI spices. Focusing on efficiency aligns with sustainability goals and offers cost-saving benefits.

“In the past, there was more regard for production than energy saving. The main focus for factory managers was producing the product as fast as possible in high quality. Since roughly a decade, strong environmental regulations such as air filtering requirements, emission fees, and energy peak penalties have been driving change and creating the need to find new solutions in Germany and elsewhere in Europe,” says Andreas Ring, a team manager at Etteplan in Leverkusen, Germany.

“Asset management is crucial to address the needs of the green transition.”

Ring leads a team of 40 experts. One half specializes in process automation in all kinds of production branches with various control systems on the shop floor. The other half focuses on factory information technology, controlling and correlating the data information flow from the shop floor to the ERP System level by various solutions such as EMS or Manufacturing Executions Systems (MES). The experts help several leading German customers develop tailored asset and energy management solutions.

According to Andreas Ring, the ability to control the energy consumption of assets has become an integral part of asset management. He emphasizes the value of analyzing real-time data on power consumption. It enables informed decisions that contribute to both efficiency and sustainability.

“We developed a Peak Performance Management System for a German customer, based on recorded value calculation of energy consumption forecast in 15-minute intervals,” Ring explains. “When a new order comes to the production line, we can switch off non-essential energy consumers and use alternative sources like diesel generators to avoid peak hour loads. This level of real-time monitoring is necessary for managing energy use efficiently.”

At the same time, asset management provides relief to factory managers who want to prevent costly downtime and enhance the lifespan of assets. Particularly powerful is integrating Artificial Intelligence and machine learning into industrial processes. Collecting and analyzing data from sensors and assets with new digital technologies enables predicting equipment failures, allowing for timely maintenance and reducing energy waste and emissions.

“One chemical customer is permitted to burn polluted air only three times a year in the event of a problem. If they must make it more often, they must pay a penalty fee. Naturally, they must find ways to avoid this. By predictive maintenance, they can detect problems beforehand and get them under control,” Ring says.

Etteplan's collaboration with Henkel showcases the transformative potential of integrated asset and energy management systems. Headquartered in Germany, Henkel is a global company specializing in chemical and consumer goods, aiming to become climate-positive by 2040. The company employs about 53,000 people, and its sales exceeded 19 billion euros in 2020.

Henkel’s electricity data is gathered into a big data lake, ensuring reliable collection across all sites. Even weather data is incorporated, and report generation is automated.

“We are managing the digital platform that collects and analyzes the data. Our solutions help Henkel monitor energy consumption in real time, perform lifecycle analyses, and even consider the impact of subcontractors. This holistic approach is essential for achieving their ambitious climate targets,” Ring adds.

Etteplan implemented an Energy Management System that enables the integration of production data and energy data KPIs and reporting for global ISO 50001 solution at Henkel. The solution reduced Henkel’s year-on-year energy consumption by 18% and improved the Overall Equipment Efficiency (OEE) by 15% by supporting Henkel with their OEE, a big data project, and SAP integration. To summarize, Henkel can stay ahead of regulatory requirements and maintain its commitment to sustainability without compromising productivity.

Etteplan’s interdisciplinary team, comprising process and software engineers, provides customized solutions that enhance energy efficiency and overall productivity.

“Our advantage is having all these roles under one roof," says Andreas Ring. "This allows us to develop tailored solutions that meet the specific needs of our clients, from energy management to advanced asset management and predictive maintenance.”

As demonstrated by Etteplan’s work with Henkel and other clients, integrating energy management with asset management not only reduces emissions but also enhances operational efficiency and resilience. For European industrial companies, embracing these practices is a pathway to long-term success and competitiveness in evolving markets.

Are you curious to know more about combining asset management and energy system management effectively to both manage energy costs and improve the sustainability of operations? Check out "Seven ways to reach efficient asset operations".