Smart Energy platform for Freyconsa

Smart Energy by Sener: Energy monitoring and carbon footprint control platform

Sener has created a tailored monitoring, control and action platform for Frenos y Conjuntos SA.

Freyconsa (Frenos y Conjuntos SA), a manufacturer of automotive components, has entrusted Sener with the development of a Smart Energy platform, to monitor and optimise lighting and compressed air system (valves and compressors), automatically adjusting to production demands at its plant in Valladolid (Castile and León).

This platform is designed to provide detailed tracking of energy consumption and carbon footprint of its production process in a detailed manner, allowing for disaggregation by production line, reference, or part. This will enable energy to become a key driver in plant operations and provide detailed information on the environmental footprint of the products.

Sener’s Smart Energy Platform development for monitoring, control, and action was executed in three stages:

Stage 1

Designed database architecture and deployed the platform.
Incorporated energy consumption data from a sensor-equipped production line and compressor.
Integrated with production (MES) and planning data.
Developed screens, KPIs, reports, and alarms featuring historical data, consumption, and carbon footprint forecasts.

Stage 2

Provided smart prescriptions and supported sensor installation (network analysers, flow meters) on additional production lines and compressors.
Expanded functionalities to cover all production lines and compressors.
Introduced advanced alarms and line-to-line comparisons.
Monitored non-productive consumption, such as lighting.

Stage 3

Provided smart prescriptions and supported sensor installation (network analysers, flow meters) on additional production lines and compressors.

Expanded functionalities to cover all production lines and compressors.
Introduced advanced alarms and line-to-line comparisons.
Monitored non-productive consumption, such as lighting.

Client objetives

Strengthen the company’s sustainability strategy

and provide customers with detailed carbon footprint data for supplied products.

Automatically generate audit reports compliant with ISO 50001 standards.

Unify the different sources of data

on energy and production to analyse energy impacts broken down per production line and product.

Improve understanding and control of energy use,

enabling tailored energy efficiency measures and supporting transformative decarbonisation and fuel-switching initiatives.

Characteristics of the project

Energy consumption and carbon footprint monitoring

Tracks consumption and carbon footprint with granular breakdowns by production line, reference, or part, integrating energy as a core operational factor in the plant.

Three-stage development

Progresses from monitoring energy, production, and planning data to implementing control and actionable outcomes.

Advantages

Forecasts air needs per production line,

enabling precise valve adjustments at the entrance of each line to optimise consumption where required and eliminate waste.

Achieves energy efficiency gains,

Depending on the level of effective management and the implementation of the automated solenoid valve control across branches.

XEnergy

XDispatchability and Storage

XEnergy Management System

Smart Energy platform for Freyconsa

Monitoring and optimizing energy consumption and carbon footprint