Namaste India Case Study: Energy Monitoring System for Boilers and Machines

At a Glance

• 8 boilers and 12 machines monitored in real time, with day and night shift costs
• 459 abnormal power events caught automatically in one monitored window
• 100% of stoppages tied to a recorded reason and exact energy data
• 15-20% estimated annual reduction in utility costs

About Namaste India

Namaste India is a leading Indian dairy brand from RSPL Group, with its plant at Shivrajpur, Kanpur. It makes fresh milk, curd, lassi, butter, paneer, ghee, UHT milk, dairy whitener, ice cream and other dairy products. With heating, drying and refrigeration running around the clock, energy is one of its biggest costs, so real-time visibility was essential.

Brief

Namaste India, a food and beverage manufacturer in Kanpur, Uttar Pradesh, wanted to understand where its boilers and machines were using energy and what each shift cost. IOTMATRIX’s team studied the plant, audited every boiler and machine, and set up one Energy monitoring system across the New and Old Buildings. The plant now has live, department-wise visibility of its energy use, automated energy management & control and annual utility costs have fallen by an estimated percentage.

The Problem

The call from Namaste India was simple. After the initial call, our expert team met them to understand their setup and challenges. When our engineers asked how much energy each boiler and machine used, and what it cost per shift, they had no clear answer. They only had the monthly electricity bill, which showed how much they paid, but not where the energy went or why costs were rising.

What their team told us:

• Boilers ran above their rated limits, with no data on how much or how often
• No exact figures for energy use or its cost
• No remote monitoring, and the night shift was rarely watched
• Peak demand penalties were found only after the bill arrived
• Machine stoppages had no recorded reason or cost
• Mechanical problems kept recurring, with no clear cause
• Parts failed without warning, leading to rushed repairs
• Maintenance was reactive, not based on actual condition
• Electrical faults (tripping, overloads, unstable supply) were hard to trace

They wanted to monitor consumption remotely and see energy use circuit by circuit, in real time.

What Namaste India Gained

Namaste India now has full visibility of its plant. Energy use for all 8 boilers and 12 machines is measured, with cost calculated by shift, and managers can check the plant from anywhere, including the night shift, without being on site. The system caught 459 abnormal power events automatically in a single dashboard, and live alerts give the team time to act before a peak demand penalty. Every stoppage is now tied to a recorded reason and exact energy-use data, so electrical faults come with a time, a location and a pattern, and fault finding is much faster.

Early signals on load and electrical behaviour now let the team address problems before a part fails, and servicing goes where it is actually needed. Automated reports replaced manual data collection, so decisions rest on real numbers. By watching real-time data and fixing energy leaks, Namaste India reduced annual utility costs by an estimated [15-20%].

From Guesswork to Control

With IOTMATRIX’s MatrixIQ, Namaste India moved from guessing about energy to managing it. Every boiler, machine and department is now monitored in real time across both the New and Old Buildings, problems are caught early, and decisions rest on real data. The result is better control, fewer surprises and lower utility costs.