Overview
When a devastating fire tore through a major manufacturing facility in Eswatini, it brought production to a halt. The incident destroyed much of the plant’s infrastructure, leaving the team grappling with extensive damage, significant downtime, and escalating operational costs. Yet, this setback became a turning point for progress.
Determined to rebuild smarter, Spintex Eswatini took a proactive approach—reassessing not just what was lost, but how operations could be improved moving forward. One critical area identified was energy management. The existing setup, reliant on outdated bulk meter readings, offered limited visibility into real-time power usage and efficiency. With no live monitoring or alert capabilities, the facility had previously lacked the tools to detect inefficiencies or respond to issues before they escalated. This time, things would be different.
EM stepped in to offer a comprehensive solution built around the Polar Monitoring System. Designed to eliminate human error, enhance power factor management, and provide real-time data access, Polar Monitoring formed the backbone of a robust, integrated energy management approach.
The Challenge
Challenge 1
Limited visibility and control
Before the fire, the facility relied on basic bulk meter readings with no real-time insight. Data was collected manually at intervals, creating visibility gaps and leaving the team unable to detect power issues before they escalated into unplanned and costly downtime.
Challenge 2
Inefficient power management
With monthly energy usage averaging 100,000 kWh, the facility faced significant costs—without a way to verify billing accuracy or track performance. The lack of detailed sub-metering meant inefficiencies went unnoticed, leading to possible overbilling and energy wastage.
Challenge 3
Legacy infrastructure
The existing setup—built on legacy panels and basic monitoring systems— wasn’t designed for modern energy management. It offered no flexibility to integrate advanced technologies, making it difficult to scale, adapt, or optimise for efficiency.
The Solution
Implementing a comprehensive monitoring framework with Polar Monitoring
The EM team developed a tailored solution built around the Polar Monitoring System—a cloud-based, real-time monitoring platform designed to eliminate inefficiencies and prevent future disruptions. The system provides continuous data access, customisable alerts, and seamless integration with existing infrastructure to enhance monitoring precision and scalability.
This implementation included the Lovato DMG7500 meter and Lovato Easy Branch System, both selected for their compatibility with the Polar Monitoring framework. The Easy Branch System supports tracking across multiple submeters, enabling granular insights into energy consumption throughout the facility.
Unlike conventional systems that rely on periodic or manual checks, Polar Monitoring offers continuous, real-time data access. This visibility allows operators to identify inefficiencies and detect faults as they occur, rather than reacting to problems only after they escalate. Alerts for anomalies, faults, and maintenance needs ensure that minor issues are addressed promptly, preventing costly downtime.
The solution also introduced the Polar Cloud, which provides long-term trend analysis through historical data retention of up to five years. This capability supports strategic planning and continuous optimisation, allowing the facility to track performance improvements over time.
Fig 1. The Polar Monitoring System’s live data interface provides operators with real-time insights into power factor, voltage, and energy consumption, empowering them to make data-driven decisions on the spot.
Component integration
Enhancing precision and scalability through streamlined integration
To ensure a seamless transition to the new monitoring system, EM integrated several critical components that work in concert to enhance efficiency and reliability.
| Component | Features | Benefits |
|---|---|---|
| Polar Monitoring System | Continuous data access, custom alerts, compatibility with diverse systems | Immediate fault detection, efficient power management, enhanced operational visibility. |
| Polar Dashboard | Fully customisable interface integrating multiple power sources | Real-time monitoring of hybrid setups, including generators, PV plants, batteries, and mains. |
| Polar Cloud | Data retention for up to five years | Enables historical analysis, strategic planning, and optimised performance management. |
| Polar Alert System | Fault and anomaly notifications | Early detection of issues, preventing downtime and ensuring reliability. |
Fig 2. Polar Cloud enables long-term trend analysis by retaining historical data for up to five years, supporting strategic planning and efficiency improvements.
The DMG7500 meter and Lovato Easy Branch System were integrated to expand the monitoring scope, providing detailed insights into energy usage across various operational zones. The Easy Branch System allows for monitoring of up to 32 submeters or 99 single-phase meters through a single interface, significantly improving visibility and control.
This streamlined integration ensures that every component contributes to a unified, responsive monitoring framework. Data from all devices is centralised within the Polar Monitoring System, enhancing both accessibility and reliability.
Fig 3. The Polar Monitoring System’s Devices Tab displays all connected systems, simplifying management and enhancing troubleshooting efficiency.
Technical support
Delivering expert guidance for optimal performance
EMs role extended beyond deployment. EM ensured that the Polar Monitoring System was configured to meet the facility’s specific needs, providing both technical training and ongoing support. This approach enabled the client to quickly adapt to the new system and maximise its capabilities.
Training was provided on power factor correction (PFC) to help reduce energy costs through efficient management, leveraging the DMG7500 meter for precise tracking of energy usage. The Easy Branch System’s functionality was also optimised to monitor multiple power points with minimal manual intervention.
By offering comprehensive support, the EM team ensured that the system operated as intended from day one. Ongoing guidance allowed the facility to fully harness the system’s capabilities, from real-time monitoring to predictive maintenance and historical analysis.
Results
Achieving operational excellence through intelligent monitoring
The implementation of Polar Monitoring produced several tangible benefits:
- Improved monitoring and control: Real-time access to critical data enabled operators to respond to emerging issues before they affected productivity.
- Cost savings: Enhanced monitoring capabilities allowed the facility to identify inefficiencies and optimise energy use, resulting in measurable cost reductions.
- Preventative maintenance: The alert system provided valuable early warnings, reducing downtime and safeguarding productivity.
- Strategic insights: Cloud storage facilitated historical analysis, supporting future planning and efficiency improvements.
Fig 4. Performance metrics indicate significant efficiency improvements, real-time fault detection, and enhanced operational control following the deployment of the Polar Monitoring System.
| Equipment | Benefit |
|---|---|
| DMG7500 Meter | Accurate tracking of energy usage, integrated with Polar Monitoring. |
| Easy Branch System | Supports monitoring of 32 submeters or 99 single-phase meters. |
| Lovato Controllers | Enhanced monitoring capabilities with seamless integration. |
| Power Factor Controller | Ensures efficient power management, reducing overall energy costs. |
| Polar Gateway | Connects all components to the cloud for real-time monitoring and alerts. |