A major manufacturing facility in Lagos, Nigeria, producing consumer goods for the West African market, faced escalating energy costs and frequent power disruptions that threatened production schedules and profitability.
The Challenge
The facility confronted significant energy management challenges:
- High energy costs consuming 40% of operational expenses
- Frequent power outages causing production delays
- Lack of visibility into energy consumption patterns
- Manual load management leading to inefficiencies
- No demand forecasting capabilities
The Solution
PAM AI's intelligent energy management system was deployed across the entire facility, integrating:
- 500kW solar PV installation
- 1MWh battery storage system
- Smart meters on all production lines
- PAM AI optimization algorithms
- Automated load shifting capabilities
- Real-time monitoring dashboard
Implementation and Configuration
Over a two-month deployment period, PAM AI was configured to:
- Monitor all energy-consuming equipment
- Forecast production energy demands
- Automatically shift non-critical loads during peak pricing
- Optimize battery charging/discharging cycles
- Provide alerts for unusual consumption patterns
Results Achieved
Within the first year of implementation:
- 35% Cost Reduction: Energy costs decreased from $45,000/month to $29,250/month
- 99.5% Uptime: Improved reliability through predictive maintenance
- 8-Month ROI: System paid for itself in less than a year
- 20% Productivity Increase: Reduced downtime from power issues
- Carbon Footprint: 450 tons CO2 reduction annually
- Peak Demand Reduction: 28% reduction in peak demand charges
Operational Improvements
The facility's operations manager noted: "PAM AI transformed how we manage energy. The automated load shifting means we're always operating at optimal cost, and the predictive alerts prevent expensive equipment failures."
Key Features Utilized
- Demand Response: Automatically reduced consumption during peak pricing
- Predictive Analytics: Forecasted energy needs based on production schedules
- Equipment Monitoring: Identified inefficient machinery for maintenance
- Battery Optimization: Maximized solar usage and reduced grid dependency
Scalability and Expansion
Following this success, the company is expanding PAM AI to three additional manufacturing facilities, demonstrating the scalability of intelligent energy management solutions.