Powering Operational Excellence with SSM EMS at Recron Malaysia

Industry: Polyester & TextilePlant

Locations: Nilai & Melaka, Malaysia

Product Deployed: SSM Energy Management System (EMS)

Business Challenges

Recron Malaysia, one of the world’s largest integrated polyester and textile manufacturers, is fully dependent on its own power generation system to meet production needs. Managing energy efficiently across multiple facilities was critical, yet the company faced key challenges:

• Decentralized Monitoring: No centralized visibility for energy generation and distribution across 12 locations.

• Limited Device Connectivity: Multiple devices and protocols created integration complexity.

• Energy Planning Gaps: Lack of trend-based insights made day-to-day power generation planning difficult.

• Operational Inefficiencies: Missed opportunities for optimizing power factor and improving energy utilization.

  
  

Our Solution:

To address these challenges:

Seamless Device & Data Integration

• Established a centralized data platform to unify energy generation and distribution data from all sites.

• Enabled standardized data acquisition across diverse equipment and protocols for consistent monitoring.

  
  

Real-Time Monitoring & Analytics

• Enabled real-time power monitoring across facilities.

• Delivered trend analysis dashboards to optimize power generation scheduling.

• Improved visibility of key parameters including power factor, generation load, and consumption patterns.

  
  

Enterprise-Wide Insights

• Provided a single view of energy performance across all locations.

• Enabled engineering and operations teams to make data-driven decisions for energy optimization.

  
  

Key Outcomes

• Energy Savings: Achieved 150 kW per month savings through optimized generation planning.

• Improved Production Efficiency: Night-time production output improved from 1.8 MW to 2.5 MW using trend analysis insights.

• Power Factor Optimization: Improved power quality and reduced losses, ensuring cost efficiency.

• Sustainability Gains: Reduced energy wastage and aligned with corporate sustainability goals.

  
  

Why SSM EMS?

• High Scalability: Supports large multi-plant deployments with thousands of tags.

• Protocol-Agnostic Integration: Seamlessly connects with PLCs, meters, and field devices.

• Real-Time Visibility: Empowers teams with actionable insights to optimize generation and distribution.

• Analytics-Driven Efficiency: Drives measurable energy savings and operational excellence.

  
  

SSM EMS enables Recron Malaysia to run its power generation more intelligently, reduce costs, and achieve operational excellence across its world-class facilities.

FAQs: Energy Management with SSM EMS at Recron Malaysia

What energy management challenges did Recron Malaysia face before implementing SSM EMS?

Recron Malaysia faced decentralized energy monitoring across 12 locations, limited connectivity between diverse devices and protocols, and a lack of trend-based insights for effective power generation planning and optimization.

How did SSM EMS provide centralized visibility across multiple plants?

SSM EMS established a centralized data platform that unified energy generation and distribution data from all facilities, giving teams a single, enterprise-wide view of energy performance in real time.

How did real-time monitoring and analytics improve operational efficiency?

Real-time monitoring and trend analysis dashboards enabled better power generation scheduling, improved visibility into power factor and load patterns, and supported data-driven decisions for optimizing energy utilization.

What measurable results were achieved after deploying SSM EMS?

Recron Malaysia achieved approximately 150 kW per month energy savings, improved night-time production output from 1.8 MW to 2.5 MW, optimized power factor, and reduced overall energy losses.

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