The Challenge
A manufacturing facility's electricity tariff structure included 40% premium charges for peak demand during peak windows. Peak demand was being driven by simultaneous operation of production machinery AND non-essential loads.
What Became Visible
Real-time load profiling revealed that peak demand spikes were driven by three factors: scheduled production machinery (unavoidable), cooling systems cycling at full load during peak windows (unscheduled), and auxiliary equipment left running during peak periods (unplanned). The facility was paying peak charges for loads that could have been deferred by 30 minutes.
What Changed
Automated load shedding during peak demand windows — non-essential equipment shut down automatically 5 minutes before peak, restored 5 minutes after.
How it worked: Production machinery continued uninterrupted. Cooling systems were pre-cycled before peak windows. Auxiliary equipment had scheduled ramp-down times. The facility's peak demand dropped by 15%, reducing tariff charges immediately.
Results
during peak windows
annually
no change to production
per peak windows
Peak demand charges are the most manipulable part of the electricity bill. When load profiles during peak windows become visible, the interventions are straightforward: defer what can be deferred, schedule what can be scheduled.
Operational Reality
Most facilities waste 10–20% of peak demand charges through loads that could be deferred. The fix requires data and simple automation.