Factory Energy Management

The problem

Energy is the largest variable cost after materials, but it is only known per month from the utility bill, never per line, shift or product.

Solution overview

MILESGO gateways collect data from electricity meters, gas meters, water meters, steam flow meters, production counters and machine state signals over Modbus RTU / Modbus TCP / M-Bus / S7, and deliver it to the energy management system, MES, large-screen dashboards (HDMI), a cloud platform (MQTT) as OPC UA / MQTT. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

electricity meters
gas meters
water meters
steam flow meters
production counters and machine state signals

Protocol path

Modbus RTU / Modbus TCP / M-Bus / S7 → OPC UA / MQTT

Implementation checklist for the project manager

Record CT ratios, meter IDs and multipliers in the point table; wrong multipliers are the usual cause of billing errors.
Agree KPI definitions (for example OEE components or kWh per unit) with operations before building dashboards.
Fix a site / asset naming convention before the first site so data from all sites can be compared.
Do not modify validated PLC programs; read existing data areas or add gateway-side mapping instead.
Configure NTP so trends, alarms and meter readings carry consistent timestamps.
Roll out in phases: pilot one site or area, confirm data quality, then replicate.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

System architecture

Field layer: electricity meters, gas meters, water meters, steam flow meters, production counters and machine state signals, connected over Modbus RTU / Modbus TCP / M-Bus / S7. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: the energy management system, MES, large-screen dashboards (HDMI), a cloud platform (MQTT), which receives the data as OPC UA / MQTT. Remote access for maintenance runs over VPN rather than open internet ports.

System composition

Field devices: electricity meters, gas meters, water meters, steam flow meters, production counters and machine state signals
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: the energy management system, MES, large-screen dashboards (HDMI), a cloud platform (MQTT) (OPC UA / MQTT)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Software and AI capabilities

Consumption baseline and deviation alertsPilot
Load and consumption forecastingRoadmap

Delivery steps

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Customer value

Consumption visible by area, system and time period
Consumption attributable by tenant, department or cost centre
Reliable trend data for optimisation and fault diagnosis
Timestamped records for compliance and reporting

Tell us about your project

Send the protocols, point count and target system. A sales and engineering pair reviews every submission.

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