Environmental Monitoring System
Industrial IoT Case Study
How a Sail Loft Reduced Energy Costs in 30 Days, Achieving ROI in Just 5 Months
Table of Contents
This Industrial IoT case study demonstrates how data-driven monitoring and process optimization can deliver significant savings for companies.
The value of combining technology with strategic planning can be observed even in small, targeted, and data-informed interventions. By adhering to these principles, it is possible to achieve tangible improvements measurable in terms of efficiency, cost reduction, and higher quality standards.
THE CLIENT
A medium-sized Italian sail loft specializing in the production and repair of racing and cruising sails, with workshops for:
Thermal pressing and welding
Sewing and assembly
Technical fabric storage
The quality of their work depends on stable temperature and humidity to ensure:
Proper adhesion of laminates
Controlled fabric tension
Minimization of deformation
THE OBJECTIVE
Reduce energy consumption while maintaining optimal conditions for production processes.
THE CHALLENGE
Before our intervention:
No continuous monitoring of environmental conditions
Manual and non-optimized use of heating and cooling systems
Systems switched on “by feel,” often prematurely or for longer than necessary
TECHNOLOGY IMPLEMENTED
We installed a real-time temperature and humidity monitoring system in:
Pressing Area
Macros Area
Data was collected and analyzed around the clock to map environmental conditions, identifying:
Time periods where natural cooling was sufficient
Peaks in humidity and temperature limited to certain hours
Differences between areas requiring localized adjustments
SOLUTIONS IMPLEMENTED
Based on the data collected, we were able to:
Delay the start of cooling systems in cooler areas → fewer operating hours = lower energy consumption
Activate humidifiers only when critical humidity thresholds were reached, avoiding continuous operation
Schedule sensitive processes (e.g., pressing) during the most stable time windows (9:00–12:00)
RESULTS ACHIEVED (After 30 Days)
35% reduction in energy consumption for heating and cooling systems
Improved process quality: fewer defects caused by thermal expansion or improper adhesion
Enhanced operational control: managers now use data to plan shifts and production processes
Return on Investment achieved in just 5 months from energy savings alone
Dopo un percorso maturato tra esperienze commerciali e imprenditoriali, fonda Automation-Kriz, software house specializzata nello sviluppo di soluzioni avanzate per il controllo di processo e l’innovazione tecnologica in ambito industriale. È esperto nello sviluppo in Python e C++, robotica, programmazione CNC, cloud e mobile development, oltre che in UX e testing.