PROJECT OVERVIEW

METALLOPLASTIKI AGRINIOU ABEE, one of the most active industrial providers of metal and plastic solutions in Greece, was facing increasing challenges in the field of energy efficiency. High electrical energy consumption, voltage sags, severe current and voltage harmonics, and limited power reserve were negatively affecting the company’s competitiveness, production stability, and sustainable expansion. The need for immediate energy savings and addressing these challenges was imperative.

SOLUTION

SENERQON GROUP designed and implemented an integrated energy-saving project using Artificial Intelligence (AI) models, optimizing power quality, stabilizing voltage across electrical loads, and increasing the efficiency of electric motors and transformers. The approach included:
- Measurements and recordings of basic quantities (Voltage, Current, Active Power, Reactive Power, etc.) as well as current and voltage harmonics up to the 35th order, including transient phenomena. Advanced recording devices such as the PQ-BOX 200 portable oscilloscope by Eberle were used.
- Collection of theoretical data of the electrical installation (Single-line diagrams, Transformer and Motor specs, Inverter specs, etc.) and their analysis using AI models (Multi-Layer Perceptron Neural Networks).
- Scientific study based on the above measurements and theoretical analysis, with simulations of system operation to identify all issues. Simulations used advanced AI algorithms (XGBoost) trained from finite element model applications verified by real post-installation measurements.
- Design and construction of customized interventions based on the scientific study results, tailored for METALLOPLASTIKI’s factory:
• Custom panels by RITTAL adapted to operational conditions.
• Siemens PLCs controlling dynamic characteristics of interventions, using software built with AI algorithms and study results.
• Custom power electronics, inductors, and capacitors (Siemens, ABB, Schneider Electric, Merus Power), all designed and manufactured specifically for the site using simulation results.
- Installation and parallel connection of customized solutions without disrupting production. All preliminary work (panel installation, cable routing, etc.) was done during normal operations, and final connections were completed during a scheduled maintenance stop.

RESULTS & BENEFITS

1. MEASURABLE ENERGY BENEFITS
• 12.2% total energy savings after approximately eight months of operation, surpassing the guaranteed 9.6%.
Assessed using two independent methodologies:
A) CONSUMPTION MEASUREMENTS
Comparative consumption with SENERQON interventions ON/OFF, under stable electrical conditions and different production scenarios.
B) ARTIFICIAL INTELLIGENCE MODEL
AI model trained using production data, raw materials, temperature, dates, and energy consumption (MLP & XGBoost). Prediction error before implementation: only -0.35%. The model calculated expected consumption without the project and compared it to actual data post-implementation, confirming the 12.2% savings with high accuracy.

2. TECHNICAL & OPERATIONAL BENEFITS
• 28% reduction in apparent power → increased power reserve → avoids future transformer/panel upgrades.
• 77% reduction in electrical maintenance cost due to reduced current and heat load on all equipment.
• Harmonics reduced below 5% (current) and 2% (voltage), down from 47% and 6.3% respectively.
• Optimized efficiency of all electrical components (VFDs, motors, transformers, cables).
• Stabilized voltage even during dips up to 2 sec → reduced unplanned stops → less downtime and raw material loss.

3. FINANCIAL BENEFITS
• Investment payback time: just 2.08 years.
• Permanent operating cost reduction, lower future expansion cost, enhanced competitiveness.

WHY THIS PROJECT STANDS OUT

- Achieved energy savings significantly above guaranteed target.
- Multiple business benefits that directly improve competitiveness.
- Use of advanced AI for simulation, intervention design, dynamic control, and savings verification.
- Specialized technical solutions — not standard commercial products.
- Measurable, sustainable, and documented results.
- Fully implemented industrial project — not a pilot or a study.
- Model of digital transformation in energy management.