Syncross Energy Management SystemEvery panel, machine and room in one live view

MDB / DB panels, machines, office, compressors, transformers and solar PV stream live data into the Syncross EMS dashboard. Click a source, or take the tour.

Factory energy challenge
Factory energy challenge

Factories consume energy every second. But do you know where it is going?

Syncross EMS helps energy and sustainability teams move from delayed reports to live, actionable energy intelligence across machines, departments, and complete plants.

Hidden energy losses

Identify abnormal consumption, idle load, and invisible wastage across the factory.

High peak demand

Detect load spikes before they become expensive demand charges.

No machine visibility

See consumption by line, machine, panel, department, or tenant.

Manual reporting delays

Replace spreadsheet-heavy energy reporting with automated dashboards and reports.

Poor power factor

Monitor power factor and take corrective action before losses increase.

Power quality issues

Track harmonics, dips, surges, imbalance, and electrical disturbances.

No carbon tracking

Convert energy consumption into carbon visibility for sustainability reporting.

Delayed fault detection

Get smart alerts for voltage issues, meter faults, and consumption spikes.

Animated data flow

How factory energy data connects with Syncross EMS

The architecture below shows the full live energy data journey from factory equipment to the EMS dashboard and AI recommendations.

01

Factory devices

  • Energy meters
  • MDB / DB panels
  • Machines
  • Compressors
  • Transformers
  • Solar PV
kWhkWCurrent
02

Control layer

  • PLC integration
  • SCADA integration
  • Machine panels
  • Utility systems
  • Meter networks
ModbusOPC UA
03

Edge gateway

  • Data collection
  • Protocol conversion
  • Local buffering
  • Secure transfer
  • Site connectivity
MQTTEdge
04

Syncross EMS

  • Energy analytics
  • Power quality
  • Carbon tracking
  • Peak demand
  • AI insights
AICloudOn-prem
05

Dashboards

  • Web dashboard
  • Mobile app
  • Alerts
  • PDF / Excel reports
  • Recommendations
ReportsAlerts
Syncross EMS dashboard

Live energy dashboard for complete factory visibility

Monitor consumption, demand, power quality, alerts, carbon, and energy saving opportunities from one operations view, fed by the meters, panels, machines, compressors, transformers and solar PV above.

SYNCROSSEnergy › Power & energyLive · Factory-01--:--:-- · user@ems.syncross.ai
Details View ⌄
Today ⌄
01/10/2024 - 10/10/2024
☁ Online
SIEMENS  PAC3120
Consuming now
3 Phase Balanced
Voltage in range
No wire-break

Active Power

LIVE
0 kW
Avg. 0 kW
+ 0% ↑
Reactive power540.44 kVAr
Apparent power540.44 kVA

Energy

ConsumptionTotalizer
0 kWh
↑ 3,566.4 kWh
↓ 3,566.4 kWh

Total harmonic distortion

CurrentPower
A
49.8 %
B
75.1 %
C
39 %

Electricity availability

online
offline

Parent devices

Parent devices 1
Parent devices 2

Child devices

Child devices 1
Child devices 1
Child devices 1
Child devices 1
Child devices 1

Transformers

LIVE
TR-1 loading
71 %
TR-2 loading
64 %
TR-1 temperature
58 °C
TR-2 temperature
55 °C
LV voltage 398.4 V, incomer power factor 0.96

Load by feeder

LIVE
MDB-1 Production
612 kW
MDB-2 Compressors
270 kW
DB-3 Utilities
238 kW
DB-5 Lighting and HVAC
164 kW
Total feeder load 1,284 kW

Load by line

LIVE
Line 1 Press
288 kW
Line 2 Assembly
196 kW
Line 3 Packing
156 kW
Idle load
48 kW
Idle load after shift on Line 2

Compressors

LIVE
Compressor 1
Loaded
Compressor 2
Modulating
Compressor 3
Standby
Specific power 6.4 kW/100cfm, air leakage 8%

Demand profile today (kW)

LIVE
Amber bars are near the daily peak. The dashed line is the 1,500 kW demand limit.

Peak demand

LIVE
1,412 kW
Forecast peak around 18:30, limit 1,500 kW

Energy cost today

LIVE
11.8 thousand
Tariff applied, target 12.5 thousand

Cost by department

LIVE
Production
52 %
Utilities
24 %
Compressed air
14 %
Lighting and HVAC
10 %

Power factor

LIVE
0.96 PF
No penalty risk, target above 0.95

Solar generation vs plant load (kW)

LIVE
Solar generation Plant load

Solar PV

LIVE
Generating now412 kW
Generated today2.9 MWh
Share of plant load32 %
Grid export0 kW

Carbon today

LIVE
4.8 tCO2
Avoided by solar: 1.4 tCO2

Carbon by area

LIVE
Machines
2.4 tCO2
Compressors
1.1 tCO2
Lighting and HVAC
0.8 tCO2
Utilities
0.5 tCO2

Active alerts

LIVE
Chiller meter offlineMeters, 21 min ago
Peak demand risk expected at 18:30MDB, now
Voltage dip on the Line 2 meterMeters, 8 min ago
Idle load on Line 2 after shiftMachines, 1 h ago
Compressor 2 modulating above needCompressors, 2 h ago

Alert summary

1Critical
3Warnings
1Information

Reports

Daily energy reportSent 06:00
Weekly power qualityMon 08:00
Monthly ESG reportReady
PDF
Excel

AI recommendations

AIIdle load found after shift on Line 2: 48 kW that can be switched off.
AIShift HVAC load by 20 minutes to stay under the 1,500 kW limit.
AIRun a compressed air leak survey: leakage is about 8% of output.

Office room: air conditioning and lighting

LIVE
Air conditioner 24.1 °C 5.4 kW 1.3 kW · 520 lux 3 people · 640 ppm Condenser
The air conditioner, six LED ceiling panels and occupancy sensors report to the Syncross gateway every second.

Air conditioning

LIVE
Cooling load
5.4 kW
Compressor speed
62 %
Room temp
24.1 °C
Supply air
14.2 °C
Setpoint 24 °C, mode Cool, fan Auto

Lighting

LIVE
Panels on
6 of 6
Dim level
82 %
Light level
520 lux
Lighting power
1.3 kW
Auto-dim follows daylight and occupancy

Comfort and occupancy

LIVE
3People in the room
640 ppmCO2 level
48 %Humidity

Office load

LIVE
8.6 kWOffice total
5.4 kWAir conditioning
1.3 kWLighting
Office load, last 40 readings (kW)
✓
Live power and energySee active power, energy, harmonics and power factor in one view.
✓
Sources, demand and carbonTrack transformers, feeders, solar, peak demand, cost and carbon.
✓
Office air conditioning and lightingFollow office load, room temperature, occupancy and lighting live.
EMS features

Everything you need to control energy performance

From power quality and energy cost allocation to carbon tracking and predictive insights, Syncross EMS is built for real industrial environments.

Real-time Energy Monitoring

Track active, reactive, and apparent power across machines, departments, and the entire plant.

Power Quality Monitoring

Monitor harmonics, THD, voltage dips, surges, imbalance, flicker, and transients.

Carbon Emission Tracking

Convert energy usage into carbon visibility for sustainability and ESG reporting.

Peak Demand Monitoring

Identify demand spikes, load peaks, and abnormal consumption before they increase cost.

Equipment-Level Breakdown

See consumption by machine, production line, department, utility, or process.

Predictive Energy Insights

Use AI to detect anomalies, idle loads, inefficiencies, and equipment risk signals.

Smart Alerts

Get alerts for abnormal consumption, voltage issues, poor PF, meter faults, and load spikes.

Automated Reports

Generate energy reports for management, audits, sustainability, and compliance.

Cost Allocation

Track energy cost by department, tenant, production line, or machine with tariff logic.

AI energy intelligence

From energy data to AI-powered decisions

Syncross EMS analyzes factory energy behavior to surface anomalies, savings opportunities, operational risk, and executive-level insights.

1
Anomaly and idle load detectionIdentify abnormal consumption, idle load, energy loss and power quality issues across machines and panels.
2
Peak demand predictionForecast load peaks and get early warnings before they turn into demand charges.
3
Production vs energy correlationCompare output with energy use, benchmark machines and spot predictive maintenance signals.
Syncross AIDemo dataOnline
Business impact

Reduce energy cost. Improve efficiency. Support sustainability.

Clear outcomes for energy, production and sustainability teams.

↓Energy consumption reduction through visibility and corrective action
↘Peak demand control with early warnings and load profile analytics
CO₂Carbon emission tracking for sustainability and audit-ready reporting
24/7Live dashboards for faster reporting and real-time decision-making
PFImproved power factor and better electrical system visibility
AIAnomaly detection to identify waste, faults, and energy risks earlier
↑Better machine-level visibility for production and utility teams
ReportingAutomated reporting for management, compliance, and energy audits
Why Syncross EMS

Built for industrial environments, not just energy charts

✓

Real-time industrial energy visibility

Monitor live energy and electrical parameters across factory assets.

✓

Machine and department tracking

Break down consumption by machine, line, department, process, or tenant.

✓

AI-powered anomaly detection

Identify abnormal consumption, idle load, and power quality risk early.

✓

Custom dashboards and reports

Configure dashboards, alerts, reporting cycles, and management views.

✓

Edge + cloud architecture

Deploy for factory realities with secure site-level data collection.

✓

Sustainability-ready

Support carbon tracking, energy improvement, and audit-ready reports.

Let's Talk

Ready to transform your factory into a smart, data-driven operation?

Book a walkthrough with our industrial IoT team and see Syncross running on data like yours.

Book a DemoTalk to an IIoT Expert