Energy and CO₂ monitoring on Ignition
See energy use per line, per machine and per product, find waste, and calculate CO₂, with the meters and PLCs you already have.
We build energy and CO₂ monitoring on Inductive Automation Ignition. Data comes from the energy meters, drives, PLCs and gas or steam flow meters already in the plant, plus new meters where needed. Ignition stores it, shows energy per line, machine and product, and raises alerts for abnormal use, such as a high base load during stops. CO₂ is calculated from the energy data with the emission factors you choose. Our Factory Assistant can explain deviations in plain language. For larger energy users, the same data supports the energy audits and energy management systems required by the EU Energy Efficiency Directive (EU) 2023/1791.
What you see
- Electricity, gas, steam and compressed air per line and per machine
- Energy per tonne or per unit, once production counts are linked
- Base load during stops, nights and weekends, and the peaks
- CO₂ per line, product and month, with the factors you choose
- Comparisons between shifts, recipes and lines
Alerts
Abnormal consumption for the current production state, for example compressors or heaters running during a stop, a meter that stops counting, or a slow rise in energy per tonne that points to a maintenance issue. Alerts come with the data behind them.
What it connects to
For example energy meters over Modbus TCP, Siemens PLCs and drives, existing SCADA databases and production data from MES or ERP exports. We specialise in Siemens and Ignition and connect other systems where needed. Reports export to Excel or CSV for your energy auditor.
Why now: the EU Energy Efficiency Directive
Directive (EU) 2023/1791, Article 11, sets two thresholds based on average annual energy consumption over the previous three years, all energy carriers together:
| Consumption | Obligation | Date |
|---|---|---|
| Above 85 TJ (about 23.6 GWh) | Energy management system, certified by an independent body | By 11 October 2027 |
| Above 10 TJ (about 2.8 GWh), without such a system | Energy audit, then at least every four years; action plan, with plans and implementation rate published in the annual report | First audit by 11 October 2026 |
Both need measured data per energy user. National rules add details, so check them with your energy advisor. Monitoring does not replace the audit or the certified system; it delivers the data they need.
How we deliver it
- Meter inventory. What is measured today, what is missing, and which data is already in PLCs or SCADA.
- Connect. Meters and PLC data into Ignition, read-only towards production systems.
- Dashboards and reports. Built with your energy and production teams, per line and per product.
- Alerts. Rules for abnormal use, tuned on real data so they do not flood.
- Handover. Training, documentation, and the Factory Assistant on top if you want answers in plain language.
Questions we get
Do we need Ignition?
It is our preferred platform: Inductive Automation licenses it per server, with unlimited tags and clients. If you already run another SCADA, we can start from its data.
Can we use the data for official CO₂ reporting?
We calculate CO₂ from measured energy with the factors you choose and document the method. Whether a report is accepted for official purposes is up to your auditor.
Do we need new meters?
Often only a few. The meter inventory shows what is already measured, including data that sits unused in PLCs and drives.
Can AI help here?
Yes. The Factory Assistant can answer questions such as why energy per tonne rose this week, with the data behind the answer.
Sources
A new line, an upgrade, or AI for your plant?
Tell us about your project and we will set up a technical call.
2800 Mechelen, Belgium E-mail: info@simsolutions.be Enterprise no. / VAT: BE 0680.932.773