Electrical Management System (EMS) | Ako získať kontrolu nad spotrebou elektriny vo vašej firme | How to Gain Control Over Electricity Consumption in Your Company

Electrical Management System | How to Gain Control Over Electricity Consumption in Your Company

by Industrial IoT

Today, most companies are aware that electricity costs increasingly impact their profitability and competitiveness. Yet many still operate without systems that would allow them to monitor, analyze, and optimize electricity consumption in real time. The solution may be an EMS – Electrical Management System, which brings companies transparency, automation, and measurable savings.

Electrical Management System (EMS) | Ako získať kontrolu nad spotrebou elektriny vo vašej firme | How to Gain Control Over Electricity Consumption in Your Company

What is EMS (Electrical Management System)?

EMS – Electrical Management System is a system designed for detailed monitoring, analysis, and control of electricity consumption in production halls or office buildings. It collects data from electricity meters, transformers, switchboards, or directly from devices, providing an accurate picture of when, where, and why energy is being lost—and how it can be used more efficiently.

Electrical Management System vs. Energy Management System

When discussing energy efficiency and automation, it’s important to distinguish what EMS actually refers to, as the acronym can mean two different levels:

  • Electrical Management System focuses specifically on monitoring and managing electricity consumption. It tracks voltage, current, outages, demand peaks, and enables optimization of electrical equipment and switchboard operation.
  • Energy Management System is a broader concept that monitors and evaluates the consumption of all energy media—including electricity, gas, water, heat, compressed air, and steam.

This article focuses primarily on the Electrical Management System, since in production and technology operations, electricity is often the most significant cost and the most critical part of the infrastructure.

What Problems Do Companies Face Without EMS?

❌ Without a modern EMS, companies often rely on outdated data that only arrives on the end-of-month bill, making it impossible to respond in time to sudden consumption changes or unexpected cost increases.

❌ Energy monitoring is mostly manual—entering meter values into spreadsheets or taking photos. This method is time-consuming, error-prone, and does not allow for ongoing evaluation.

❌ Equipment often runs during weekends, holidays, or shutdowns. Without automation, systems remain active even when unused—leading to major energy losses simply because the system can’t respond to changes in operational status.

❌ There’s no integration between systems, so managers must log into multiple apps to piece together the big picture. This delays decision-making and increases the risk of mistakes.

❌ Companies without EMS cannot effectively evaluate their carbon footprint or track ESG (Environmental, Social, Governance) performance—both increasingly important for reputation and business relations.

❌ Accurate allocation of energy costs between departments, lines, or tenants fails. This leads to internal confusion and unnecessary conflicts that hinder planning and responsible resource management.

How Does EMS Work in Practice?

A modern EMS acts as the brain of energy management. It collects data from sensors, meters, switchboards, and PLC units. All data is then visualized in clear dashboards (e.g., using the Ignition platform), enabling analysis by object, department, production line, or time period.

But EMS is not just a passive monitoring tool. It can alert you in real time to limit breaches, faults, or unusual fluctuations, and it can actively control equipment operations based on predefined rules or live data—such as automatically switching off lights during inactivity or lowering heating on weekends.

Thanks to automated cost allocation across operations, EMS saves time, increases accuracy, and simplifies planning. The collected data is immediately usable for decision-making. Management can respond in real time, identify the root causes of issues, and take action that truly impacts cost and performance.

Importantly, this is not a one-time process. EMS should function as a system of continuous improvement. Through repeated data evaluation, rule adjustments, and automation fine-tuning, its efficiency can be gradually increased. This approach enables companies to optimize consumption, reduce waste, and achieve higher sustainability and economic efficiency.

Why Is EMS Implementation Worth It?

✅ EMS allows companies to immediately reduce costs—not only by identifying unnecessary usage, but also by optimizing demand peaks and inefficient equipment operation.

✅ Managers no longer rely on estimates or outdated reports—they make decisions based on accurate, real-time data. With EMS integrated with all key systems, all data is centralized, accelerating decisions.

✅ EMS can autonomously control device operations based on set schedules or real-time conditions. This reduces manual intervention and lowers costs without compromising operations.

✅ From a sustainability and ESG perspective, EMS is an invaluable tool. It provides accurate, trustworthy data for reporting on carbon footprint, environmental goals, and legal compliance.

✅ EMS offers detailed consumption monitoring down to individual devices, lines, departments, or rented spaces, significantly simplifying internal billing and financial planning.

✅ EMS significantly enhances operational safety. It can detect faults or grid overloads early, helping to prevent breakdowns, serious damage, and unnecessary expenses.

✅ Finally, a modern EMS system is essential for meeting ISO 50001 requirements. This certification confirms that the company actively manages its energy efficiency and reduces environmental impact.

A Comprehensive Tailored Solution from IoT Industries

Want to gain control over electricity consumption in your company?

Contact us. Together, we’ll design a modern, tailored EMS solution that gives you a clear view of where your energy is being wasted—and concrete steps to turn those losses into savings.

Why Choose IoT/IIoT Implementation with IoT Industries?

Traditional companies typically specialize in OT (operational technologies, such as production lines and devices) or classic enterprise IT systems. However, we are able to connect both of these worlds. Our unique expertise in integrating OT and IT allows us to deliver innovative solutions in digital transformation, enhancing efficiency, reliability, and competitiveness for manufacturing companies.

Ako znížiť režijné náklady vo výrobe pomocou digitálnej transformácie? | How to Reduce Overhead Costs in Manufacturing with Digital Transformation?

How to Reduce Overhead Costs in Manufacturing with Digital Transformation?

by Industrial IoTSCADA/MES

Overhead costs make up a significant portion of manufacturing expenses, yet many companies fail to give them sufficient attention. While direct production costs, such as material expenses and wages, are easily measurable, overhead costs often remain hidden in excessive energy consumption, unnecessary downtime, and inefficient processes. The result is higher expenses, lower productivity, and reduced competitiveness.

With modern digital solutions like SCADA (Supervisory Control and Data Acquisition), MES (Manufacturing Execution System), EMS (Energy Management System), and BMS (Building Management System), companies can not only accurately identify sources of unnecessary overhead costs but also significantly reduce them.

Ako znížiť režijné náklady vo výrobe pomocou digitálnej transformácie? | How to Reduce Overhead Costs in Manufacturing with Digital Transformation?

What Are Overhead Costs in Manufacturing?

Overhead costs include all expenses that are not directly linked to producing a specific product but still impact the entire manufacturing process. These typically include:

  • Energy costs – electricity, gas, water, cooling, heating
  • Maintenance and repairs – unplanned downtime, machine failures, service interventions
  • Inefficient production planning – downtime, material waste, underutilized workforce

Many companies accept these expenses as an unavoidable part of manufacturing. However, the truth is that modern technologies can significantly optimize them.

What Are the Most Common Issues That Increase Overhead Costs?

❌ High Energy Consumption and Inefficient Operational Costs

Manufacturers often lack a detailed overview of which machines consume the most energy and where waste occurs. It is common for machines to remain powered even when idle, heating and lighting to run in unused spaces, and production cycles to be poorly optimized for energy efficiency. As a result, energy expenses continue to rise.

❌ Inefficient Maintenance and Frequent Downtime

Many companies still rely on reactive maintenance — fixing machines only after they break down. This leads to unplanned downtime, delays, and increased costs for urgent repairs. A more effective approach is implementing digital planned maintenance and condition-based maintenance, which monitors key parameters such as oil temperature or bearing vibrations, allowing companies to address issues before they result in breakdowns. Once these levels are established, businesses can advance to predictive maintenance using advanced data analysis.

❌ Poor Planning and Underutilized Production Capacity

Lack of accurate data results in inefficient production planning. Machines operate with low efficiency, employees wait for materials, and inventory levels spiral out of control. Poor planning also means that production is not flexible enough to quickly respond to shifts in demand.

How Can Digital Transformation Reduce Overhead Costs?

✅ Optimizing Energy Consumption with EMS and BMS

An Energy Management System (EMS) provides companies with real-time insights into energy consumption across different production areas. A Building Management System (BMS) uses this data to automate energy regulation, shut down unnecessary machines, and optimize production cycles to significantly reduce energy costs.

✅ Immediate Failure Response and Smart Maintenance with SCADA and MES

Supervisory Control and Data Acquisition (SCADA) continuously monitors production equipment and allows for immediate responses to malfunctions through remote control. It also provides essential data for optimizing maintenance strategies—whether planned, condition-based, or predictive. Manufacturing Execution System (MES) further integrates this data into the broader production context.

✅ More Efficient Production Planning with MES

MES connects ERP systems with real-time production data, improving the efficiency of manufacturing operations. This reduces downtime, enhances workforce utilization, and optimizes material inventory, leading to significant cost savings.

Overhead Costs – Example of Savings Calculation

A company that pays €30,000 per month for electricity can reduce consumption by 15–20% using EMS and BMS, resulting in annual savings of up to €72,000. Similar savings can be achieved in maintenance, logistics, and overall production process optimization.

The Key to Successful IoT/IIoT Implementation

Many companies struggle with where to start when optimizing their overhead costs. The solution lies in a detailed analysis of manufacturing processes and the implementation of intelligent control systems. At IoT Industries, we offer tailored solutions – from cost analysis and the implementation of MES, SCADA, EMS, and BMS systems to long-term support and production optimization. Contact us to find out how you can reduce your overhead costs.

Why Choose IoT/IIoT Implementation with IoT Industries?

Traditional companies typically specialize in OT (operational technologies, such as production lines and devices) or classic enterprise IT systems. However, we are able to connect both of these worlds. Our unique expertise in integrating OT and IT allows us to deliver innovative solutions in digital transformation, enhancing efficiency, reliability, and competitiveness for manufacturing companies.

Systémy BMS a EMS a ich vplyv na energetickú efektívnosť a dlhodobú udržateľnosť | BMS and EMS Systems and Their Impact on Energy Efficiency and Long-term Sustainability

BMS and EMS Systems and Their Impact on Energy Efficiency and Long-term Sustainability

by Building and Data Center Monitoring

In today’s business environment, which faces increasing demands to reduce costs and improve productivity, reducing energy consumption and optimizing building management are crucial. Despite this, many companies still operate without centralized systems, leading not only to higher costs but also to issues with flexibility, competitiveness, and compliance with legislative requirements. However, BMS and EMS systems can effectively address these challenges.

Systémy BMS a EMS a ich vplyv na energetickú efektívnosť a dlhodobú udržateľnosť | BMS and EMS Systems and Their Impact on Energy Efficiency and Long-term Sustainability

What does company management look like without BMS and EMS systems?

Imagine a company that does not yet use centralized systems for energy and building management. Managers receive an energy bill every month but see only the total consumption without a detailed overview of where energy is used the most and where the greatest losses occur.

In such companies, most consumption data is collected manually. Employees walk around meters, write down their readings on paper or document them with photos, and then transfer the data into spreadsheets. This process is not only time-consuming but also prone to errors. Moreover, it does not provide ongoing consumption information, so if there is an unexpected cost increase, the company only learns about it at the end of the month—by which time it is too late to address the issue.

In various operational modes, such as weekends or during downtimes, a system without automation lacks flexibility. Systems cannot shut down or switch to energy-saving modes when not in use. As a result, lighting, air conditioning, or heating continue to operate even when no one is using them, leading to unnecessary consumption that the company could otherwise easily optimize.

For example, in one company monitoring energy consumption, it was discovered that even during a complete production shutdown, energy consumption decreased by only 50%. This revealed that some systems remained active and consumed energy despite not being in use — highlighting the need for more effective automation.

Another problem is the lack of integration between individual systems. Lighting, heating, ventilation, security, and fire systems operate independently, requiring separate management. If a manager needs an overview of the entire building’s status, they must log into multiple applications, significantly increasing response time when addressing issues and reducing management efficiency.

With increasing demands to reduce carbon footprints and achieve higher energy efficiency, there is also greater emphasis on meeting environmental and legislative standards. Without a quality system for monitoring consumption, a company can easily exceed set limits or fail to meet ESG (Environmental, Social, Governance) requirements. These are criteria that assess a company’s environmental, social, and governance impact. This can lead to penalties and reputational damage. Companies that cannot demonstrate compliance with environmental standards may also lose competitiveness in a market where environmentally responsible partners and customers increasingly prefer to work with sustainable businesses.

For many companies, a key issue is also the allocation of energy costs among departments, production lines, or tenants, such as external operations (e.g., cafeterias). Without an automated system for consumption allocation, the company still has to rely on manual readings, which causes time delays and may lead to inaccuracies.

What are BMS and EMS systems, and how do they help solve all these problems?

BMS (Building Management System), also known as a building automation system, primarily focuses on monitoring and managing building equipment such as lighting, heating, ventilation, air conditioning, security, and fire systems. BMS provides a centralized overview of the status of all key systems and enables their automation according to various operational modes. This allows a company to optimize energy consumption and, in turn, reduce costs.EMS (Energy Management System) focuses on measuring and analyzing energy consumption to identify areas where a company can reduce its energy costs. EMS enables continuous monitoring of consumption and detailed analysis of data from individual sources. This helps companies not only optimize their overall energy consumption but also allocate energy costs across different operations.Although both systems can operate independently, the ideal solution is their integration, which provides companies with maximum benefits. Ignition, a platform used by us at IoT Industries, combines BMS and EMS into a single unified system.

How does Ignition help with BMS
and EMS?

The Ignition platform provides a comprehensive tool for data collection, analysis, and automated management in real-time. This process consists of several key steps:

  1. Data Collection – Ignition can collect data from a wide range of devices and systems using protocols such as Modbus, BACnet, OPC UA, or MQTT. In the case of EMS, this includes data from measuring instruments that monitor electricity, water, gas, or heat consumption. For BMS, Ignition allows direct monitoring of devices such as lighting, air conditioning, or heating.
  2. Data Analysis – With clear graphs and visualizations on interactive dashboards, a company can analyze consumption trends, compare different periods, and identify areas where costs are highest. Within the EMS, the system allows for analyzing consumption down to the level of individual departments, production lines, or tenants, which simplifies cost allocation and facilitates financial planning.
    Practical Example: In one manufacturing company, a backup diesel generator automatically started after a power outage. When the main power was restored, the generator did not shut down, and because the old system sent too many notifications, employees failed to notice that the generator continued running. The diesel fuel was gradually depleted, and when the next power outage occurred, the backup source could no longer start. By implementing the Ignition platform, which centralizes data collection and analysis on a clear dashboard, managers can instantly see the current status of backup sources, other components, and data centers critical to the company’s operations with just one glance.
  3. Automation and Optimization – Ignition can automatically manage the operation of devices based on predefined rules or real-time data. For example, the system can reduce heating or turn off lighting during weekends or downtimes, thus optimizing consumption. This automation also ensures that the building operates efficiently without the need for manual intervention.
  4. Taking Action – The ultimate goal of data collection and analysis is to enable company management to take active measures based on current information. Ignition allows for quick and accurate decision-making, which helps prevent unnecessary costs and supports long-term efficiency.

    However, the entire process is not a one-time effort—it should be continuously evaluated and improved by repeating steps 1–4. In this way, the system is constantly refined, contributing to even higher levels of efficiency and sustainability.

Benefits of Implementing BMS and EMS Systems

Implementing Ignition as a platform for BMS and EMS brings immediate and long-term benefits to companies. The main advantages include:
  1. Reduced Energy Costs – Automated device management and energy consumption optimization help the company effectively reduce costs.
  2. Flexible Cost Allocation – Detailed monitoring enables fair distribution of costs among different departments, production lines, and tenants, while also facilitating financial planning.
  3. Compliance with Environmental and Legislative Standards – BMS and EMS help meet strict energy efficiency standards and promote environmental responsibility.
  4. Competitive Advantage – A modern energy management system is a sign of technological advancement and environmental responsibility, which can enhance the company’s attractiveness to business partners and customers.
For companies that want to gain insight into energy consumption, streamline building management, and maintain competitiveness, BMS and EMS systems are invaluable tools. Ignition combines the capabilities of these systems into a single platform that not only monitors and analyzes consumption but also automates and optimizes the operation of all key devices in real time. Investing in BMS and EMS provides companies with immediate cost savings, compliance with legislative requirements, and a sustainable path to long-term growth.

Why IoT Industries?

Traditional companies typically specialize in OT (operational technologies, such as production lines and equipment) or conventional enterprise IT systems. However, we are able to connect both these worlds. Our unique expertise in bridging OT and IT allows us to deliver innovative digital transformation solutions to clients, enhancing the efficiency, reliability, and competitiveness of manufacturing companies.