Johnson Controls manufacturing plant identifies 52% energy savings per furnace

The plant aimed to reduce energy use and improve carbon reporting in support of the company’s wider sustainability commitments. However, limited insight into energy consumption at the furnace level made it difficult to identify inefficiencies, benchmark performance, or connect energy use to production output.

Existing metering provided only high-level utility data and left gaps that affected billing accuracy and emissions reporting. Without real-time monitoring at the equipment level, the team lacked the detailed understanding to drive consistent, measurable improvements across production.

The plant installed new metering infrastructure to collect real-time furnace energy data and integrated this information with billing and utility systems. This provided a more complete view of consumption patterns and production output, allowing the team to identify inefficiencies and correct metering errors.

OpenBlue Net Zero Plus supported analysis by enabling deeper insights into consumption trends and carbon impact. The solution was deployed as a scalable system compatible with existing operational technology, ensuring it could support future efficiency and sustainability initiatives.

The improved data also helped the team make informed decisions about future equipment upgrades, ensuring investments were based on accurate performance and consumption patterns.

Through enhanced metering and better integration of energy data, the plant achieved a 52% reduction in energy use per electric arc furnace and identified more than $150,000 in projected annual savings.

• Improved visibility into production energy and carbon impact
• More accurate tracking of cost and emissions at the equipment level

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